JP6592055B2 - New separator for electrochemical systems - Google Patents

Description

  The present invention relates to a novel separator for electrochemical systems.

[Cross-reference of related applications]
This application claims the benefit and priority of US provisional application 61 / 506,489 filed July 11, 2011 and US provisional application 61 / 622,371, filed April 10, 2012. And claims are hereby incorporated by reference in their entirety.

  Over the past decades, electrochemical storage and conversion devices have made revolutionary advances, expanding the capabilities of these systems in various fields, including portable electronic devices, aircraft and spacecraft technology, passenger cars, and biometrics. I came. Modern electrochemical storage and conversion devices have design and performance attributes that are specifically designed to provide compatibility with a wide range of application requirements and operating environments. For example, from low energy self-discharge rates for implantable medical devices and high energy density batteries with high discharge reliability, to low-cost lightweight rechargeable batteries that provide long run times for a wide range of portable electronic devices, and short-term Advanced electrochemical storage systems have been developed that span high capacity batteries for military and aerospace applications that can provide extremely high discharge rates in between.

  Despite the development and widespread adoption of this diverse range of advanced electromechanical storage and conversion systems, the need to enable a wider range of device applications by facilitating research to expand the functionality of these systems. It has been. For example, due to the large growth in demand for high-power portable electronic products, the development of safe and lightweight primary and secondary batteries that provide higher energy density has generated great interest. In addition, the demand for miniaturization in the field of consumer electronics and instrumentation continues to promote research on new designs and material strategies to reduce the size, mass, and form factor of high performance batteries. In addition, the continued development in the field of electric vehicles and aerospace engineering is also a mechanically robust, reliable, high energy density and high power density enabling good equipment performance in the operating range of operation. It creates the need for batteries.

  Many recent advances in electrochemical storage and conversion technology are directly attributable to the discovery and incorporation of new materials for battery components. For example, lithium battery technology continues to develop rapidly, at least in part due to the discovery of new electrodes and electrolyte materials in these systems. Elemental lithium has a unique combination of properties that make it attractive for use in electrochemical cells. First, it is the lightest metal in the periodic table and has an atomic mass of 6.94 AMU. Second, lithium has a very low electrochemical oxidation / reduction potential (ie, -3.045 V relative to NHE (standard hydrogen electrode)). This unique combination of properties allows lithium-based electrochemical cells to have very large specific capacities. The latest lithium ion secondary batteries provide excellent charge / discharge characteristics and are therefore widely used as power sources for portable electronic devices such as mobile phones and portable computers. Patent document 1, patent document 2, patent document 3, and non-patent document 1, which are incorporated herein by reference in their entirety, are directed to lithium battery systems and lithium ion battery systems.

  Advances in electrode material, electrolyte composition, and device geometry continue to support further development of Li-based electrochemical systems. For example, Patent Literature 4 published on March 29, 2012 and Patent Literature 5 published on March 15, 2012 disclose a three-dimensional electrode array structure of an electrochemical system including a lithium battery. Yes.

  Despite substantial progress, practical challenges remain in connection with the continued development of Li-based electrochemical systems. For example, an important issue relates to dendrite formation in primary and secondary lithium and lithium ion batteries. It is generally known that Li deposition in many electrolytes has a strong dendrite tendency and is prone to problems with these systems including short circuits, mechanical failure, and thermal runaway. Safety concerns regarding dendrite formation currently present a barrier that prevents the mounting of metallic Li anodes in rechargeable systems. Many strategies pursued, including the development of non-lithium anodes and internal safety systems that can monitor problems related to dendrite formation in real time to address the safety related to dendrite formation, particularly in the context of secondary batteries Has been.

US Pat. No. 6,852,446 US Pat. No. 6,306,540 US Pat. No. 6,489,055 US Application Publication No. 2012/0077095 International Patent Application Publication No. 2012/034042

“Lithium Sciences Science and Technology” edited by Gholam-Abbas Nazri and Gianfranco Pistoia, Kluer Academic Publishers, 2004

  As generally recognized from the above, there is a current need for lithium-based electrochemical systems that exhibit useful electrochemical properties for a range of applications. Specifically, there is a need for a lithium electrochemical system that enables good electrochemical performance and high versatility in both primary and secondary lithium batteries.

  In one aspect, the present invention provides a separator system for an electrochemical system that provides electronic, mechanical, and chemical properties useful for a range of electrochemical storage and conversion applications. Some embodiments of separator systems are structural, physical, and electrostatic that are useful, for example, in preventing electrochemical cell breakage and useful in enhancing cycle life and performance such as energy and power. Provide a special quality. A series of examples are separators that manage and control dendrite formation in metallic batteries such as lithium batteries, alkaline batteries, zinc batteries, and lead batteries. In one embodiment, for example, the separator system of the present invention provides an effective barrier to help mechanical properties, electronic internal shorts and / or thermal runaway caused by dendrites while supporting superior ion transport properties. , Having a multi-layered and porous geometric shape. Another set of examples is a multi-layer separator consisting of multiple porous / porous layers and an impermeable but ion-selective conductive film, where the porous layer is an internal short circuit such as a dendrite short circuit failure and / or thermal runaway. Provide an effective barrier to prevent failure, and the membrane layer provides an effective barrier to separate the electrolyte adjacent to the anode from the electrolyte adjacent to the cathode, and the electrodes and their surfaces and their electrolytes; By preventing contamination, cell performance such as energy, power, and life cycle can be enhanced. This is particularly useful with metal air and flow batteries and semi-solid batteries, some examples being lithium-air cells, lithium water cells, and zinc-air cells.

  In one embodiment, the present invention is a separator system for an electrochemical system, comprising: (i) a first high mechanical strength layer, and a plurality of layers provided in a first pattern through the first high mechanical strength layer A first high mechanical strength layer having an opening; and (ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer is 20% or less. A second high mechanical strength layer having an offset arrangement with respect to the first pattern, wherein the first high mechanical strength layer and the second high mechanical strength layer are in contact with the first high mechanical strength layer and the second high mechanical strength layer. The electrolyte ions provided through the first high mechanical strength layer and the second high mechanical strength layer Is positioned such that the ability to provide a separator system. In one embodiment, for example, the first high mechanical strength layer and the second high mechanical strength layer are not in direct physical contact with each other. In an embodiment of this aspect, the overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: 10% or less. In one embodiment, for example, the separator system of the present invention may include a first high mechanical strength layer, a second high mechanical strength layer, or both, between the first high mechanical strength layer and the second high mechanical strength layer. One or more electrolytes disposed in contact with the first and second high mechanical strength layers, wherein the first high mechanical strength layer and the second high mechanical strength layer are ionically conductive, optionally allowing transport of the electrolyte in the electrochemical system .

  In one embodiment, the present invention is a separator system for an electrochemical system, comprising: (i) a first high mechanical strength layer, and a plurality of layers provided in a first pattern through the first high mechanical strength layer A first high mechanical strength layer having an opening; and (ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer is 20% or less. A second high mechanical strength layer having an offset arrangement with respect to the first pattern; and (iii) a third high mechanical strength layer, having the same spatial aperture arrangement as the first pattern through the third high mechanical strength layer. A third high mechanical strength layer having a plurality of openings provided in a third pattern having The first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer were provided in contact with the first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer. A separator system is provided that is positioned such that electrolyte ions can be transported through a first high mechanical strength layer, a second high mechanical strength layer, and a third high mechanical strength layer. In one embodiment of this aspect, the overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: 10% or less. As used throughout this description, “same spatial aperture arrangement” refers to those locations where the openings of two or more high mechanical strength layers are arranged along an axis extending perpendicularly between the high mechanical strength layers. . In one embodiment, for example, “same spatial aperture arrangement” refers to those locations where two or more high mechanical strength layer openings overlap 90% or more along an axis extending perpendicularly between the high mechanical strength layers. Point to.

  In one embodiment, the present invention is a separator system for an electrochemical system, comprising: (i) a first high mechanical strength layer, and a plurality of layers provided in a first pattern through the first high mechanical strength layer A first high mechanical strength layer having an opening; and (ii) a second high mechanical strength layer, having a plurality of openings provided in a second pattern penetrating the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer is 20% or less. A second high mechanical strength layer having an offset arrangement with respect to the first pattern; and (iii) a third high mechanical strength layer, having the same spatial aperture arrangement as the first pattern through the third high mechanical strength layer. A third high mechanical strength layer having a plurality of openings provided in a third pattern having (i) ) A fourth high mechanical strength layer, and a fourth high mechanical strength layer having a plurality of openings provided in a fourth pattern having the same spatial opening arrangement as the second pattern penetrating the fourth high mechanical strength layer. The first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer are the first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer. Electrolyte ions provided in contact with the strength layer and the fourth high mechanical strength layer are transported through the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. A separator system is provided that is positioned as possible. In one embodiment of this aspect, the overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: 10% or less.

  In one embodiment, the present invention is a separator system for an electrochemical system, comprising: (i) a first high mechanical strength layer, and a plurality of layers provided in a first pattern through the first high mechanical strength layer A first high mechanical strength layer having an opening; and (ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along the axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is 40% or less. A second high mechanical strength layer having an offset arrangement with respect to the first pattern; and (iii) a third high mechanical strength layer, and a plurality of openings provided in the third pattern through the third high mechanical strength layer. And the third pattern extends along an axis extending vertically from the first layer or the second layer to the third layer. The first pattern and the second pattern have an overlap of 20% or less of the opening of the first high mechanical strength layer, the opening of the second high mechanical strength layer, and the opening of the third high mechanical strength layer. A third high mechanical strength layer having an offset arrangement, the first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer being a first high mechanical strength layer and a second high mechanical strength layer. And a separator positioned so that electrolyte ions provided in contact with the third high mechanical strength layer can be transported through the first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer Provide a system. In one embodiment of this aspect, the overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: The opening of the first high mechanical strength layer along an axis extending vertically from the first high mechanical strength layer or the second high mechanical strength layer to the third high mechanical strength layer, and the second high mechanical strength The overlap between the opening of the layer and the opening of the third high mechanical strength layer is 10% or less.

  In one embodiment, the present invention is a separator system for an electrochemical system, comprising: (i) a first high mechanical strength layer, and a plurality of layers provided in a first pattern through the first high mechanical strength layer A first high mechanical strength layer having an opening; and (ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer is 50% or less. A second high mechanical strength layer having an offset arrangement with respect to the first pattern; and (iii) a third high mechanical strength layer, and a plurality of openings provided in the third pattern through the third high mechanical strength layer. The third pattern has a third high machine from the first high mechanical strength layer or the second high mechanical strength layer. The overlap of the opening of the first high mechanical strength layer, the opening of the second high mechanical strength layer, and the opening of the third high mechanical strength layer along the axis extending vertically to the strength layer is 30% or less. A third high mechanical strength layer having an offset arrangement with respect to the one pattern and the second pattern; and (iv) a fourth high mechanical strength layer, and a plurality of the fourth high mechanical strength layers provided in the fourth pattern. The fourth pattern includes openings of the first high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer or the second high mechanical strength layer to the fourth high mechanical strength layer; The first pattern, the second pattern, and the third pattern so that the overlap of the opening of the second high mechanical strength layer, the opening of the third high mechanical strength layer, and the opening of the fourth high mechanical strength layer is 20% or less. A fourth high mechanical strength layer having an offset arrangement with respect to the first high mechanical strength layer, The second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer are the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. Separator system positioned so that electrolyte ions provided in contact with can be transported through the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer I will provide a. In one embodiment of this aspect, the overlap of the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: 30% or less, and the offset arrangement with respect to the first pattern and the second pattern has a first height along an axis extending perpendicularly from the first high mechanical strength layer or the second high mechanical strength layer to the third high mechanical strength layer. The overlap of the opening of the mechanical strength layer, the opening of the second high mechanical strength layer, and the opening of the third high mechanical strength layer is 20% or less, and the first pattern, the second pattern, and the third pattern The offset arrangement includes an opening in the first high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer or the second high mechanical strength layer to the fourth high mechanical strength layer, and a second high mechanical strength. An opening in the layer, an opening in the third high mechanical strength layer, and an opening in the fourth high mechanical strength layer Overlap, so that is 10% or less.

  In some embodiments, for example, a second high mechanical strength layer is provided between the first high mechanical strength layer and the third high mechanical strength layer. In some embodiments, for example, the first high mechanical strength layer is provided between the second high mechanical strength layer and the fourth high mechanical strength layer, or the third high mechanical strength layer is provided as the second high mechanical strength layer. And the fourth high mechanical strength layer. In one embodiment, the first mechanical strength layer and the second mechanical strength layer are not provided in physical contact, or the first mechanical strength layer, the second mechanical strength layer, and the third mechanical strength layer are physically provided. The first mechanical strength layer, the second mechanical strength layer, the third mechanical strength layer, and the fourth mechanical strength layer are not provided in contact with each other.

  Some separators of this aspect provide, for example, a multi-layer structure that manages dendrite formation in an electrochemical system, such as a plurality of separator layers (eg, a first high mechanical strength layer, a second high mechanical strength layer, a third high strength layer). The mechanical strength layer, the fourth high mechanical strength layer, etc.) have positive and negative electrode conductivities such that dendritic growth between the positive electrode and the negative electrode is kinetically and / or thermodynamically unfavorable. Complementary opening patterns such as microchannels or nanochannels established between the two. Some separators of this embodiment provide a barrier with multiple layers of geometry and physical properties that prevent, for example, a direct linear path leading to dendrite growth between the positive and negative electrodes, which Providing a multi-layer structure in which only the path (s) for ion transport between the positive and negative electrodes require a curved orbit that is kinetically and / or thermodynamically unfavorable for dendrite growth Obtained by. In one embodiment, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and / or the fourth high mechanical strength layer are planar, eg, substantially relative to each other. The planes of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and / or the fourth high mechanical strength layer are provided in parallel planes. In one embodiment, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and / or the fourth high mechanical strength layer is a hollow cylindrical structure, eg, substantially concentric. The curved surfaces of the cylindrical first layer and the second layer are provided in a concentric direction. As used herein, an axis extending perpendicularly from a concentric orientation is perpendicular to the central axis and extends radially from the central axis.

  The multilayer geometry of some separator systems of the present invention provides a selective overlap of the first pattern openings and the second pattern openings along an axis extending vertically from the first layer to the second layer. Provide the offset array to be provided. This aspect of the present invention is useful to prevent dendrite formation between the positive and negative electrodes of an electrochemical cell while utilizing useful ion transport properties. In some embodiments, the term “offset” is separate from one layer, such as an axis, where the opening of one high mechanical strength layer of the separator extends perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. Refers to a configuration that is offset relative to the position of the opening in another high mechanical strength layer along an axis extending to the other layer. In some embodiments, the term “offset” refers to the second high mechanical strength layer along an axis along which the opening of the first high mechanical strength layer extends perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. The high mechanical strength layer such that the opening of the first pattern of the first high mechanical strength layer is offset relative to the position of the opening of the second pattern of the second high mechanical strength layer so that it cannot be completely superimposed on the opening. The relative structure of the opening pattern of In one embodiment, for example, the first high mechanical strength layer and the second high mechanical strength layer are nanoporous and / or microporous, and the opening of the first high mechanical strength layer extends from the first high mechanical strength layer. Arranged so as not to overlap the openings of the second high mechanical strength layer along an axis extending vertically to the second high mechanical strength layer. In one embodiment, for example, two or more apertures in a first pattern, a second pattern, a third pattern, and a fourth pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. The overlap is 10% or less, and in some cases 1% or less for some applications. In one embodiment, for example, two or more apertures in a first pattern, a second pattern, a third pattern, and a fourth pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. Is selected from the range of 0% to 5%, and in some cases from the range of 0% to 1% for some applications. In one embodiment, for example, two or more apertures in a first pattern, a second pattern, a third pattern, and a fourth pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. Is equal to 0, for example exactly equal to 0. In one embodiment, for example, the overlap of openings of the first pattern, the second pattern, and the third pattern along an axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer is 10% or less. is there. In one embodiment, for example, the opening overlap of the first pattern, the second pattern, and the third pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is 0% to 5%. % Range. In one embodiment, for example, the opening overlap of the first pattern, the second pattern, the third pattern, and the fourth pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: 10% or less. In one embodiment, for example, the opening overlap of the first pattern, the second pattern, the third pattern, and the fourth pattern along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is: It is selected from the range of 0% to 5%.

  In one embodiment, for example, two or more of the first pattern, the second pattern, the third pattern, and the fourth pattern include substantially complementary patterns. In one embodiment, for example, substantially complementary patterns correspond to each other's substantially negative images. As used herein, a complementary pattern is the relative position of an opening of one pattern of a high mechanical strength layer and an opening of one or more other high mechanical strength layers of one or more other patterns. Refers to a configuration selected to prevent dendrite growth between the positive and negative electrodes of the electrochemical cell. In one embodiment, for example, the substantially complementary pattern of the first pattern and the second pattern is, for example, a mutual negative image, and the position of the opening of the first pattern is in the region of the second layer having no opening. Correspond. As an example of a complementary pattern of the present invention, the first layer may be characterized by an opening pattern corresponding to a black square on the chess board, and the second layer may be characterized by an opening pattern corresponding to a red square on the chess board. As an example of the complementary pattern of the present invention, the first high mechanical strength layer has a first periodic opening pattern characterized by a first pitch and opening spacing, and the second high mechanical strength layer has the same pitch and opening spacing. But having a second periodic opening pattern offset or translated from the position of the opening of the first pattern, the opening of the first high mechanical strength layer becomes the first high mechanical strength layer and the second high mechanical strength layer. So as not to be superposed on the opening of the second high mechanical strength layer along an axis extending perpendicularly from.

  In one embodiment, a separator system having three or more high mechanical strength layers may include several high mechanical strength layers having the same pattern (ie, non-complementary patterns), which may be complementary patterns. Only if the at least one layer is positioned between high mechanical strength layers having the same pattern. For example, the separator system can be characterized by one or more high mechanical strength layers having pattern A and one or more high mechanical strength layers having pattern B, where A and B are repeating arrays of ABA In a multi-layer system with a complementary pattern arranged according to

  In another embodiment, a separator system having three or more high mechanical strength layers may include only a high mechanical strength layer having a complementary pattern. For example, the separator system features one or more high mechanical strength layers having pattern A, one or more high mechanical strength layers having pattern B, and one or more high mechanical strength layers having pattern C. A, B, and C are arranged in accordance with the ABC repeating sequence, each being a complementary pattern to the other two patterns, and more in multi-layer systems that include four or more high mechanical strength layers. Long sequences (eg, ABCABC) and altered sequences (eg, ABCBA, ABCA) are possible.

In another aspect, the present invention provides one or more of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer provided on one side. A separator system further comprising a low ionic resistance layer is provided. In one embodiment, for example, each of the one or more low ionic resistance layers is an electrolyte-containing reservoir that provides, for example, a reservoir for the electrolyte of an electrochemical cell. In one embodiment, for example, one or more low ionic resistance layer independently, 20 .OMEGA.cm ² or less, preferably for some embodiments 2Omucm ² or less, the 1 .OMEGA.cm ² or less preferably some embodiments Has ionic resistance. In one embodiment, for example, at least one of the one or more low ionic resistance layers includes a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, and a fourth high mechanical strength. A pressure buffer providing a space for an electrolyte provided between at least two of the layers;

  In one embodiment, for example, at least one of the high mechanical strength layer and at least one of the one or more low ionic resistance layers are in at least one of the high mechanical strength layer and the one or more low ionic resistance layers. It is a deposited storage tank. In one embodiment, for example, at least one of the high mechanical strength layer and the one or more low ionic resistance layers is a deposited layer deposited on an electrode of an electrochemical cell, such as a positive electrode facing an electrolyte of an electrochemical cell. It is a layer deposited directly on the surface of the electrode or negative electrode. In one embodiment, for example, at least one, and possibly all, of the one or more low ionic resistance layers are applied to the first high mechanical strength layer, the second high mechanical strength layer by pressure, heat, or chemical adhesion. The third high mechanical strength layer and the fourth high mechanical strength layer are adhered to at least one side. In one embodiment, for example, at least one, and possibly all, of the one or more low ionic resistance layers are made of polymer resin, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer. The layer and the fourth high mechanical strength layer are adhered to at least one side. In one embodiment, for example, at least one, and possibly all, of the one or more low ionic resistance layers comprises a microporous material, a woven material, or a non-woven material.

  In one embodiment, for example, at least one, and possibly all, of the one or more low ionic resistance layers comprises a ceramic or glass electrolyte, a polymer electrolyte, or another solid electrolyte. In one embodiment, for example, the low ionic resistance layer comprises a glass electrolyte such as LIICON or LIPON, or a polymer electrolyte such as PEO. In one embodiment, for example, at least one, and possibly all, of the one or more low ionic resistance layers is a perforated ceramic separator, a porous ceramic separator, a perforated glass separator, a porous glass separator, or a perforated Metal, or porous alloy separator, or porous rubber, or rubber mesh, or metal mesh, or alloy mesh.

  In one embodiment, for example, at least one of the one or more low ionic resistance layers is a frame having a ring or central opening, such as a mechanical support structure, an electrolyte reservoir structure, and / or a spacer in an electrochemical cell. Includes a ring or frame structure that provides the structure. In one embodiment, for example, the one or more low ionic resistance layers are at least one of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, and a fourth high mechanical strength layer. It includes one or more frame layers in contact. In one embodiment, for example, the first high mechanical strength layer is provided between the first frame layer and the second frame layer, and the second high mechanical strength layer is provided between the third frame layer and the fourth frame layer. Alternatively, the first high mechanical strength layer is provided between the first frame layer and the second frame layer, and the second high mechanical strength layer is provided between the second frame layer and the third frame layer. In one embodiment, for example, the one or more low ionic resistance layers are one or more in physical contact with at least one electrode of an electrochemical system, such as a positive electrode and / or a negative electrode of an electrochemical cell. Includes frame layer. In one embodiment, for example, the one or more low ion resistance layers include a spacer provided between the first layer and the second layer, and the spacer includes the first layer and the second layer of 10 nm to 1000 μm. In some cases, the selected distance is selected from the range of 1 μm to 1000 μm. In one embodiment, for example, the spacer of this aspect can be a ring that defines a selected distance between the first high mechanical strength layer and the second high mechanical strength layer, a frame structure having a porous wall component, a material layer, or a separate layer. Including material element arrangements.

  In one embodiment, for example, each of the low ionic resistance layers, possibly all independently, polymer, ceramic, wood, glass, mineral, metal, alloy, woven material, non-woven material, cellulose, wood fiber, sponge Body, or a combination thereof. In one embodiment, for example, each of the one or more low ionic resistance layers is independently greater than 50%, preferably greater than 70% for some applications, preferably greater than 90% for some applications. Has porosity. In one embodiment, for example, each of the one or more low ionic resistance layers is independently selected for a porosity selected from the range of 50% to 95%, preferably in the range of 70% to 95% for some applications. Having a porosity selected from

  In one embodiment, for example, at least one side of one of the high mechanical strength layers has wettability, eg, wettability to the electrolyte of an electrochemical cell. In one embodiment, for example, the separator configuration is characterized in that the wettable surface of the high mechanical strength layer is disposed adjacent to another high mechanical strength layer without a low ionic resistance layer therebetween. . In one embodiment, for example, the separator configuration is characterized in that the wettable surface of the high mechanical strength layer is disposed adjacent to the electrode with no low ionic resistance layer in between. In one embodiment, for example, the separator is applied to another low ionic resistance layer or high mechanical strength layer, or applied to an electrode of a chemical cell, such as a positive or negative electrode of an electrochemical system. Includes a low ionic resistance layer or a high mechanical strength layer.

  In another aspect, the invention provides at least one of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, or one or more low ionic resistance layers. Provided is a separator further comprising one or more chemical barrier layers on one side. Separators with one or more chemical barriers are useful in electrochemical systems with positive and negative electrodes in contact with different electrolytes, so the chemical barrier (s) can transport charge carriers Prevent electrolyte transport. In such a configuration, the chemical barrier is useful to protect the electrode from degradation and / or to allow the use of different electrolytes at the positive and negative electrodes of the electrochemical cell. In one embodiment, for example, the one or more chemical barrier layers independently prevent the transport of undesirable chemical components through the one or more chemical barrier layers to the positive or negative electrode of the electrochemical cell. In one embodiment, for example, the one or more chemical barrier layers prevent electrolyte solvent transport through the one or more chemical barrier layers to the positive or negative electrode of the electrochemical cell. In one embodiment, for example, the one or more chemical barrier layers include a solid electrolyte or a solid polymer electrolyte disposed on at least one side of the electrode of the electrochemical cell. In one embodiment, for example, the one or more chemical barrier layers comprise a solid electrolyte from LISICON or NASICON, or a polymer electrolyte comprising polyethylene oxide (PEO).

  In one embodiment, for example, the separator system is a component of an electrochemical cell having a negative electrode and a positive electrode, the one or more chemical barrier layers include an ion conductive protective film, and the protective film is a positive electrode. Providing a barrier between the first electrolyte in contact with the second electrolyte and the second electrolyte in contact with the negative electrode, and the ion conductive protective film prevents contact between the negative electrode and the first electrolyte. In one embodiment, for example, the negative electrode is a lithium metal electrode, and the ion conductive protective film passes lithium ion charge carriers and prevents contact between the lithium metal electrode and the first electrolyte.

  In one embodiment, for example, the ion conductive protective film is made of a material selected from the group consisting of a vitreous or amorphous active metal ion conductor, a ceramic active metal ion conductor, and a glass ceramic active metal ion conductor. Including. In one embodiment, for example, the one or more chemical barrier layers further comprise a solid polymer electrolyte disposed between the surface of the protective membrane and the positive or negative electrode. In one embodiment, for example, at least one of the high mechanical strength layer, the one or more low ionic resistance layers, and the one or more chemical barrier layers is a high mechanical strength layer, one or more low ionic resistances. And a deposited layer deposited on at least one of the layer and one or more chemical barrier layers. In one embodiment, for example, at least one of the high mechanical strength layer, the one or more low ionic resistance layers, and the one or more chemical barrier layers is a deposited layer deposited on an electrode of an electrochemical cell. . In one embodiment, for example, the separator is at least two of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, and a fourth high mechanical strength layer, one or more chemical barrier layers. One combination without any low ion resistance layer.

  In one aspect, the separator is a third high mechanical strength layer, and further includes a third high mechanical strength layer having a plurality of openings provided in a third pattern through the third high mechanical strength layer. The mechanical strength layer is positioned between the first high mechanical strength layer and the second high mechanical strength layer, and the third pattern is formed from the first high mechanical strength layer or the second high mechanical strength layer to the third high mechanical strength layer. Having an offset arrangement with respect to the first pattern or the second pattern such that the overlap between the opening of the first pattern or the second pattern and the opening of the third pattern along the axis extending vertically to the layer is 20% or less . In one aspect, the separator is a fourth high mechanical strength layer, and further includes a fourth high mechanical strength layer having a plurality of openings provided in a fourth pattern through the fourth high mechanical strength layer. The mechanical strength layer is positioned between the first high mechanical strength layer and the second high mechanical strength layer, and the fourth pattern is the fourth high mechanical strength from the first high mechanical strength layer or the second high mechanical strength layer. The first pattern, the second pattern, or the first pattern, the second pattern, or the overlap so that the opening of the first pattern, the second pattern, or the third pattern along the axis extending vertically to the layer and the opening of the fourth pattern is 20% or less An offset arrangement is provided for the third pattern.

The layers of the multi-layer separator system of the present invention are configured to provide useful mechanical properties for specific applications and can be attached via a wide variety of mechanisms and device configurations. In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ionic resistance layer, a frame layer, a spacer, a chemical barrier layer, or At least some, and in some cases, all of these combinations are at least partially attached to each other by pressure, heating, adhesive application, chemical adhesive, plasma treatment, or any combination thereof. In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ionic resistance layer, a frame layer, a spacer, a chemical barrier layer, or At least some of these combinations, and in some cases all, may be adhesives, epoxies, cements, PTFE, solid electrolytes, gel electrolytes, polymer electrolytes, silicone adhesives, acrylic adhesives, cyanoacrylates, stycast 1266, delta bonds 151 , PVDF, PVA, LIPON, LIICON, PE-PP-PVDF, tetramethylammonium hydroxide pentahydrate (CH ₃ ) ₄ NOH · 5H ₂ O, poly (ethylene oxide) (PEO), epichlorohydrin and ethylene oxide P (ECH— co-EO) and poly (vinyl alcohol) copolymers Glass fiber polymer electrolyte, zinc sulfide, silicon dioxide, Kapton tape, polyethylene oxide or polypropylene Pile based Sid, or _{copolymers, PVDF-co-HFP Bi 2} O 3, fluorine-containing binder or an aromatic binder, lithium polyacrylate, or their Are at least partially attached to each other.

In one embodiment, the present invention provides a separator system further comprising one or more solid electrolyte layers, wherein the one or more solid electrolyte layers are, for example, water molecules, CO ₂ , O ₂ , or air. Is transported through the separator system and includes LISICON or NASICON.

  In one aspect, the separator of the present invention further comprises one or more electrolytes, such as an electrolyte of an electrochemical cell, which comprises a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer. , Optionally in physical contact with at least a portion of the fourth high mechanical strength layer, low ionic resistance layer, frame layer, spacer, chemical barrier layer, or any combination thereof. In one embodiment, for example, the separator system is a component of an electrochemical cell having a positive electrode and a negative electrode, the separator further comprising an electrolyte provided between the positive electrode and the negative electrode, wherein the electrolyte is a first electrode. Contact with any of the high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. In one embodiment, for example, the separator system is a component of an electrochemical cell having a positive electrode and a negative electrode, and the separator further comprises a first electrolyte and a second electrolyte provided between the positive electrode and the negative electrode. The first electrolyte has a composition different from that of the second electrolyte, and the first electrolyte includes the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. And the second electrolyte is in contact with any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. The first electrolyte and the second electrolyte do not mix with each other due to the presence of a permeable ion conductive layer or due to different chemical and physical properties such as hydrophilic or hydrophobic behavior or density. .

  The selection of physical, chemical and electronic properties of the separator system components such as the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer is highly A combination of resistance, high ionic conductivity, and useful mechanical properties are selected to provide net separator properties useful for applications in electrochemical cells.

  In one embodiment, for example, the first opening pattern provides a first porosity of the first high mechanical strength layer of 30% or more, preferably more than 40% in some applications, and / or a second opening. The pattern provides a second porosity of the second high mechanical strength layer of greater than 30%, preferably greater than 40% in some applications. In one embodiment, for example, the first opening pattern provides a first porosity of the first high mechanical strength layer of 30% or more, preferably more than 40% in some applications, or the second opening pattern is Providing a second porosity of the second high mechanical strength layer of more than 30%, preferably more than 40% in some applications, or the third opening pattern is more than 30%, preferably in some applications Provides a third porosity of the third high mechanical strength layer of greater than 40%, or a fourth opening pattern of 30% or more, preferably greater than 40% of some applications. Provides a fourth porosity. In one embodiment, for example, the first opening pattern provides a porosity of the first high mechanical strength layer selected from the range of 30% to 70%, preferably 40% to 70% for some applications; The second opening pattern provides a porosity of the second high mechanical strength layer selected from the range of 30% to 70%, preferably 40% to 70% for some applications. In one embodiment, for example, the first opening pattern provides a porosity of the first high mechanical strength layer selected from the range of 30% to 70%, preferably 40% to 70% for some applications; Or the second opening pattern provides a porosity of the second high mechanical strength layer selected from the range of 30% to 70%, preferably 40% to 70% in some applications, or the third opening pattern is 30% to 70%, preferably providing a porosity of the third high mechanical strength layer selected from the range of 40% to 70% in some applications, or the fourth opening pattern is 30% to 70% Providing the porosity of the fourth high mechanical strength layer, preferably selected from the range of 40% to 70% in some applications.

  A range of geometric shapes, shapes, orientations, and patterns of openings in the high mechanical strength layer are useful in the separator of the present invention. In one embodiment, for example, the openings in any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, or the fourth high mechanical strength layer are independently circular, parallelograms, , A rectangle, a square, a triangle, an ellipse, a rectangle, a pentagon, a hexagon, and a cross-sectional shape selected from any combination thereof. In one embodiment, for example, the opening in the high mechanical strength layer is 20 μm or more, in some embodiments 50 μm or more, in some embodiments 200 μm or more, and in some embodiments in some embodiments. At least one lateral dimension (eg, length, width, diameter, etc.) of 500 μm or more. In one embodiment, for example, the opening in the high mechanical strength layer has at least one lateral dimension between 1 μm and 1 mm, and in some applications between 200 μm and 1 mm. In one embodiment, for example, the opening of the high mechanical strength layer has at least one lateral dimension of 200 μm or less, in some applications 10 μm or less, and in some applications 1 μm or less. In one embodiment, for example, any of the first pattern, the second pattern, the third pattern, or the fourth pattern is independently a symmetric opening pattern or an asymmetric opening pattern. In one embodiment, for example, any of the first pattern, the second pattern, the third pattern, or the fourth pattern independently includes a non-random opening pattern.

  In one embodiment, for example, either the first opening pattern, the second opening pattern, the third opening pattern, or the fourth opening pattern is independently laser cutting, lithography, etching, casting, drilling, molding, stamping, Formed by a process selected from the group consisting of patterning, coating, and any combination thereof.

  In one embodiment, the first high mechanical strength layer, and / or the second high mechanical strength layer, and / or the third high mechanical strength layer, and / or the fourth high mechanical strength layer are non-conductive, for example, One or more of these layers includes an electrically insulating material to prevent direct electrical contact between the positive and negative electrodes of an electrochemical system such as an electrochemical cell. The electrically insulating high mechanical strength layer may include a range of electrically insulating materials, such as Kapton, polyethylene, polypropylene, fibrous cellulose, and / or metal layers coated with an electrical insulator such as PE and PP coatings. In one embodiment, at least one of the first high mechanical strength layer and / or the second high mechanical strength layer and / or the third high mechanical strength layer and / or the fourth high mechanical strength layer is, for example, conductive. One or more of these layers comprises an electrically insulating material and one or more of these layers comprises a conductive material. The first high mechanical strength layer, and / or the second high mechanical strength layer, and / or the third high mechanical strength layer, and / or the fourth high mechanical strength layer are characterized by shape memory characteristics such as a shape memory polymer. Includes materials or materials characterized by superelastic properties.

  In one embodiment, for example, the first high mechanical strength layer and the second high mechanical strength layer are not in full physical contact with each other, for example, with the first high mechanical strength layer to allow the electrolyte to transport ions. Provided in a configuration having at least some space between the second high mechanical strength layer, for example, the first high mechanical strength layer and the second high mechanical strength layer are physically attached at some points. The other points are provided by having rough surfaces in contact with each other so as to have a space in between. In one embodiment, the first high mechanical strength layer and the second high mechanical strength layer are not in physical contact. In one embodiment, for example, the first high mechanical strength layer and the second high mechanical strength layer are separated by a distance selected from the range of 20 nm to 2 mm. In one embodiment, for example, the first high mechanical strength layer or the second high mechanical strength layer is separated from the third high mechanical strength layer or the fourth high mechanical strength layer by a distance selected from the range of 20 nm to 2 mm. .

  In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, one or more low ionic resistance layers, and one or more Any of the chemical barrier layers, in some cases all independently selected in the range of 10 nm to 1 mm, in some cases in the range of 1 μm to 500 μm, in some cases in some cases Having an average thickness selected in the range of 10 nm to 50 μm. In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, one or more low ionic resistance layers, and one or more Any of the chemical barrier layers, in some cases all independently selected in the range of 5 μm to 1 mm, in some cases in the range of 25 μm to 5 mm, in some cases in some cases Having an average thickness selected in the range of 100 μm to 2 mm in some applications, and in some cases in the range of 500 μm to 1 mm in some applications. In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, one or more low ionic resistance layers, and one or more Any of these chemical barrier layers, in some cases all independently, have an average thickness selected in the range of 10 nm to 2 μm, or selected in the range of 2 μm to 50 μm.

In one embodiment, for example, any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, It has a Young's modulus selected in the range of 500 GPa. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, 5 MPa to It has a yield strength selected in the range of 1000 MPa . In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer may be independently 0. It has a tear strength selected in the range of 005N to 10N, and preferably has a tear strength in excess of 0.01N in some applications. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, 10N to It has an initial tear strength selected in the range of 500N, preferably an initial tear strength in excess of 50N for some applications. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, It has a tensile strength selected in the range of 2 GPa. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all may be independently from 10 Ncm to It has an impact strength selected in the range of 1000 Ncm.

  In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, in parallel configuration Including a planar layer. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all are independently concentric. A hollow cylindrical layer provided in the configuration is included. In one embodiment, for example, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, one or more low ionic resistance layers, and one or more Any or all of the chemical barrier layers may comprise a chemical resistant material. In one embodiment, a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, one or more low ionic resistance layers, and one or more chemistries The barrier layer is independently chemically compatible with the electrolyte provided in contact therewith and / or independently chemically compatible with the electrode provided in contact therewith.

  In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, in some cases, all independently, A material having the above melting point is included. In one embodiment, for example, at least two of the high mechanical strength layers have different melting temperatures having a difference of at least 30 ° C., and in some cases, the difference in melting temperature of the high mechanical strength layers is one of the layers. Providing a blocking mechanism that closes the ion path between the two electrodes of the electrochemical cell, or alternatively, the difference in melting temperature of the high mechanical strength layer can be achieved by melting one of the layers. It does not provide a blocking mechanism that closes the ion path between the two electrodes of the electrochemical cell. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, in some cases, all independently, 50 ppm / Including a material having a coefficient of thermal expansion of less than or equal to ° C.

The first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer of the separator system of the present invention are selected for a specific application such as the type of electrochemical cell. A range of materials may be included. In one embodiment, for example, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer independently comprise a chemical resistant material. In one embodiment, for example, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer independently comprise a thermally stable material. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, optionally all independently, a polymer, It includes one or more materials selected from the group consisting of metals, alloys, ceramics, wood, glass, semiconductors, woven materials, and non-woven materials. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all are independently 50 or more. A material having a dielectric constant of In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, in some cases, all independently, the conductive material including. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, and in some cases, all independently, the gel electrolyte One or more materials selected from the group consisting of: a solid electrolyte; and a polymer electrolyte. In one embodiment, for example, any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer, in some cases, all independently, Acid (PAA), Crosslinked polyethylene (PEX, XLPE), Polyethylene (PE), Polyethylene terephthalate (PET, PETE), Polyphenyl ether (PPE), Polyvinyl chloride (PVC), Polyvinylidene chloride (PVDC), Polylactic acid ( PLA), polypropylene (PP), polybutylene (PB), polybutylene terephthalate (PBT), polyamide (PA), polyimide (PI), polycarbonate (PC), polytetrafluoroethylene (PTFE), polystyrene (PS), polyurethane ( PU), polyester (PE), acrylonitrile butadiene Tylene (ABS), poly (methyl methacrylate) (PMMA), polyoxymethylene (POM), polysulfone (PES), styrene-acrylonitrile (SAN), ethylene vinyl acetate (EVA), styrene maleic anhydride (SMA), PVDF, PEO PVDF, LIPON PVDF, LISON PVDF, tetramethylammonium hydroxide pentahydrate (CH ₃ ) ₄ NOH · 5H ₂ O, poly (ethylene oxide) (PEO), epichlorohydrin and ethylene oxide P (ECH-co-EO) and poly (Vinyl alcohol) copolymer, PEO-PVA-glass fiber polymer electrolyte, zinc sulfide, silicon dioxide, PVA and PSA, PVA / V6 / PSS, PVA6 (PSS + PAA), V6 / PVA (PSS + P A), PVMPSS + PAA (35%)) / (PSS + PAA (35%)), (PSS + PAA (35%)) / PVA / (PSS + PAA (35%)), or (PSS + PAA (35%)) / (PVA (10%) ) + PSS (20%) vs. PVA)) / (PSS + PAA (35%)) polyethylene glycol, polypropylene glycol, polybutylene glycol, acrylic polyethylene glycol, acrylic polypropylene glycol, alkyl polybutylene glycol, copolymers thereof, PEO materials, or PVA materials And one or more materials selected from combinations thereof.

  In one embodiment, for example, the surface of any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer has wettability to the electrolyte. In one embodiment, for example, the surface of any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer is wettable with respect to the electrolyte. Apply coating. In one embodiment, for example, at least a part of the surface of any one of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer is optionally provided with a surface. Apply an adhesive coating covering less than 10%. In one embodiment, for example, at least part of the surface of any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer has a thickness of less than 5 μm. An adhesive coating having a thickness is applied. In one embodiment, for example, at least one surface of any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer ranges from 1 nm to 100 nm. The first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, or the fourth high A space for electrolyte is provided between at least a portion of the mechanical strength layer. In one embodiment, for example, the separator system is a component in an electrochemical cell having a positive electrode and a negative electrode, the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth At least one surface of any of the high mechanical strength layers has a surface roughness such as a surface roughness characterized by rms selected from the range of 1 nm to 1000 nm, the first high mechanical strength layer, the second high strength layer, A space for an electrolyte is provided between the mechanical strength layer, the third high mechanical strength layer, or the fourth high mechanical strength layer and the positive electrode or the negative electrode of the electrochemical cell. In one embodiment, for example, the surface roughness is between 5 nm and 5 micrometers between at least two portions of the high mechanical strength layer or between at least a portion of the high mechanical strength layer and the positive or negative electrode. Provides a distance selected from a range of.

In one aspect, the present invention provides a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ion resistance layer, a frame layer, a spacer, a chemical barrier layer. At least some, or any combination thereof, provides a separator system having a high surface energy, preferably a surface energy of 10 mJ / m ² or higher for some applications. In one embodiment, for example, the surface energy of any of these components improves the wettability of the layer to the electrolyte. In one embodiment, for example, the surface energy of any of these components serves to attach the layers to each other or to the electrodes of the electrochemical cell.

  In one aspect, the separator further comprises one or more coatings provided on any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer. . In one embodiment, for example, the one or more coatings independently include one or more non-conductive coatings. In one embodiment, for example, the one or more coatings independently comprise one or more hydrophobic and / or hydrophilic coatings. In one embodiment, for example, the one or more coatings independently comprise polyethylene glycol. In one embodiment, for example, the one or more coatings prevent mass transport from the positive electrode to the negative electrode of the electrochemical cell. In one embodiment, for example, the one or more coatings independently have a thickness selected from the range of 10 nm to 2 μm. In one embodiment, for example, the separator is for an electrochemical cell having a sulfur-based cathode, and the one or more coatings repel hydrophobic polysulfides to improve electrochemical cell performance and cycle life. In one embodiment, a hydrophobic or hydrophilic coating is provided on the sulfur-based cathode Li battery. The problem with modern sulfur-based cathode Li batteries is that the electrochemical reaction decomposes in the electrolyte, and thus there can be significant capacity loss due to the passage of material (mediated polysulfide) from the sulfur electrode to the Li electrode through the electrolyte. To prevent this problem, the separator of certain embodiments is coated with a polyethylene glycol material (hydrophilic) that prevents material passage and capacity loss by repelling hydrophobic polysulfide. The use of the coating in embodiments of the present invention is also useful to protect the Li anode from moisture, for example, by the hydrophobic coating of the separator in lithium-air and lithium water electrochemical cells.

  In one embodiment, for example, any of the first high mechanical strength layer, the second high mechanical strength layer, the third high mechanical strength layer, and the fourth high mechanical strength layer is independently Al, Ni, Cu, and It is a metal layer arbitrarily selected from the group consisting of stainless steel. In one embodiment, for example, the coating is a non-conductive coating optionally comprising PTFE, PE, PP, PVC, or polyimide.

  The present invention includes a separator system useful in a range of electrochemical systems. In one embodiment, for example, the present invention provides a separator system for a primary electrochemical cell or a secondary electrochemical cell. In one embodiment, for example, the present invention provides a separator system for a lithium battery, an alkaline battery, a zinc battery, or a lead acid battery. In one embodiment, for example, the present invention provides a separator system for lithium metal-air batteries, lithium ion batteries, lithium air batteries, Fe-air batteries, Al-air batteries, or zinc-air batteries. In one embodiment, for example, the present invention provides a separator system for a fuel cell, a flow cell system, a semi-solid cell, a 3D cell, a nano cell, a micro cell, or an electrochemical capacitor.

  In another aspect, the present invention provides (i) a negative electrode, (ii) a positive electrode, (iii) a first electrolyte provided between the positive electrode and the negative electrode, and (iv) in contact with the electrolyte. An electrochemical cell comprising a separator system of the present invention disposed between a negative electrode and a positive electrode, the separator system positioned so that electrolyte ions can be transported between the positive electrode and the negative electrode An electrochemical cell is provided. In one aspect, the separator system prevents electrical contact between the positive and negative electrodes. As will be appreciated by those skilled in the art, any of the separator systems described herein may be used in the electrochemical system of the present invention, such as an electrochemical cell.

In one embodiment, for example, the separator system is provided in physical contact with the positive and negative electrodes. In one embodiment, for example, the separator system is 1 × 10 ⁻³ S / cm or more, preferably 1 × 10 ⁻² S / cm in some applications, between the positive and negative electrodes. Provides greater ionic conductivity. In one embodiment, for example, the separator system, the positive electrode to the negative electrode is selected from the range of 0.5Ωcm ² ~25Ωcm ^2, preferably provides a net ionic resistance of less than 5Omucm ² in some applications.

  In one embodiment, the electrochemical cell further comprises a chemical barrier layer provided between the positive electrode and the negative electrode, and the electrochemical cell further comprises a second electrolyte provided between the positive electrode and the negative electrode. The chemical barrier layer prevents mixing of the first electrolyte and the second electrolyte.

  In one embodiment, for example, the offset arrangement of the high mechanical strength layer does not provide a direct linear path between the positive and negative electrodes. In one embodiment, for example, the offset arrangement prevents manufacturing defects, external objects, or short circuits via electrical contact between the positive and negative electrodes due to dendrite formation on the positive or negative electrode. Embodiments of this aspect are beneficial, for example, in minimizing or preventing electrical shorts or thermal runaway problems from the positive electrode to the negative electrode resulting from dendrite formation. Embodiments of this aspect are useful, for example, to provide electrochemical cells capable of cycle charge enhancement and / or high discharge rate performance.

  In one embodiment, for example, at least one of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ion resistance layer, a frame layer, a spacer, a chemical barrier layer One, or any combination thereof, can be by pressure, heating, adhesive application, chemical adhesive, plasma treatment, or deposition or application of another layer to one layer or electrode, or any combination thereof , At least partially attached to the positive or negative electrode. In one embodiment, for example, at least one of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ion resistance layer, a frame layer, a spacer, a chemical barrier layer One, or any combination thereof, is at least partially attached to the positive or negative electrode by an adhesive, epoxy, cement, teflon coating, solid electrolyte, gel electrolyte, or polymer electrolyte. In one embodiment, for example, at least one of a first high mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, a fourth high mechanical strength layer, a low ion resistance layer, a frame layer, a spacer, a chemical barrier layer One, or any combination thereof, includes a coating deposited on the surface of the positive or negative electrode.

In one embodiment, for example, the invention provides an electrochemical cell incorporating the separator system having a cycle capacity of at least 300 cycles, preferably at least 500 cycles for some applications. In one embodiment, for example, the present invention provides an electrochemical cell incorporating the separator system having a specific capacity of 100 mAh g ⁻¹ or higher at a discharge rate of C / 5 or higher.

  The electrochemical cell and separator system of the present invention is compatible with a range of electrolytes, including liquid electrolytes, solid electrolytes, gel electrolytes, aprotic electrolytes, aqueous electrolytes, and non-aqueous electrolytes. In one embodiment, for example, the electrolyte comprises a solid charge retention medium or gel electrode. In one embodiment, for example, the electrolyte includes a polymeric medium. In one embodiment, for example, the electrolyte comprises polyethylene oxide, polytetrafluoroethylene, polyvinylidene fluoride, a fluorine-containing copolymer, polyacrylonitrile, and any combination thereof.

In one embodiment, for example, the electrolyte comprises an alkali metal salt at least partially dissolved in one or more non-aqueous solvents. In one embodiment, for example, the electrolyte includes a solvent and a supporting salt, and the solvent is an organic carbonate, ether, ester, formate, lactone, sulfone, sulfolane, 1,3-dioxolane, ethylene carbonate, propylene carbonate, dimethyl carbonate, Diethyl carbonate, ethyl methyl carbonate, butylene carbonate, vinylene carbonate, fluoroethylene carbonate, fluoropropylene carbonate, y-butyrolactone, methyl difluoroacetate, ethyl difluoroacetate, dimethoxyethane, diglyme (bis (2-methoxyethyl) ether), Tetrahydrofuran, dioxolane, 2MeTHF, 1,2-DME, or larger glymes, sulfolane, methyl formate, methyl acetate, and Is selected from the group consisting of these, the supporting _{salt, LiPF 6, LiBF 4, LiAsF} 6, LiClO 4, LiSO 3 CF 3, LiN (CF 3 SO 2) 2, LiN (SO 2 C 2 F 5) ₂ , selected from the group consisting of any combination thereof. In one embodiment, for example, the electrolyte is a golfing agent selected from PVdF, PVdF-HFP copolymer, PAN, and PEO, and mixtures thereof, EC, PC, DEC, DMC, EMC, THE, 2MeTHF, 1, A plasticizer selected from the group consisting of 2-DME, and combinations thereof, and LiPF ₆ , LiBF ₄ , LiAsF ₆ , LiClO ₄ , LiSO ₃ CF ₃ , LiN (CF ₃ SO ₂ ) ₂ , and LiN (SO ₂ A Li salt selected from the group consisting of C ₂ F ₅ ) ₂ .

  In one aspect, the present invention provides an electrochemical cell having a first electrolyte on a first side including a positive electrode and a second electrolyte on a second side including a negative electrode, wherein the first electrolyte is a second electrolyte. And the electrochemical cell further comprises one or more chemical barrier layers including an ion conductive protective film positioned between the positive electrode and the negative electrode. In one embodiment of this aspect, the first electrolyte is an aqueous electrolyte and the second electrolyte is an aprotic electrolyte. In one embodiment of this aspect, at least one of the first electrolyte and the second electrolyte is a solid electrolyte.

  The electrochemical cell and separator system of the present invention is compatible with electrodes having a range of compositions, form factors, and device geometries. In one embodiment, for example, the negative electrode, the positive electrode, or both comprise a micro-sized material or a nano-sized material. As used herein, nanosize refers to a structure such as a particle or thin film having at least one physical dimension (eg, length, height, width, diameter, etc.) selected in the range of 1 nm to 1000 nm. Point to. As used herein, microsize refers to a structure such as a particle or thin film having at least one physical dimension (eg, length, height, width, diameter, etc.) selected in the range of 1 μm to 1000 μm. Point to. In one embodiment, for example, the negative or positive electrode is in the form of a powder, such as a mixture of active positive electrode particles and conductive particles. In one embodiment, for example, the negative or positive electrode is in the form of a thin film. In one embodiment, for example, the present invention provides an electrochemical cell wherein at least one of the positive electrode or the negative electrode is in the form of a solvated metal such as solvated lithium or a solvated lithium alloy. In one embodiment, for example, the present invention provides an electrochemical cell in which at least one of a positive electrode or a negative electrode is in the form of molten metal.

In one embodiment, for example, the invention provides that the negative electrode is lithium, zinc, aluminum, silicon, tin, antimony, lead, germanium, magnesium, cadmium, bismuth, indium, molybdenum, niobium, tungsten, tantalum, iron, nickel , manganese, copper, sodium transition metal phosphate, sodium mixed metal _{phosphates, Li 4 / 3Ti5 / 3O 4} , graphite, tin alloy, cobalt, _{carbon, LiVO 2, Li 4 Ti 5} O 12, Li4 / 3Ti5 An electrochemical cell is provided that includes a material selected from the group consisting of / 3O ₄ TiO ₂ , WO ₂ , and MoO ₂ . In one embodiment, for example, the present invention is a positive electrode, _{graphite, LiCoO_2NiO_8O 2, LiNiO 2, LiFePO} 4, LiMnPO 4, LiCoPO 4, LiMn 2 O 4, LiCoO 2, LiNiO_5Mnl. 5O ₄ , LiVPO ₄ F, silver oxide, nickel oxide, cobalt oxide, manganese oxide, AgO, Ag ₂ O ₃ , Zn, ZnO AgO, Ag ₂ O, Ag ₂ O ₃ , HgO, Hg ₂ O, CuO, CdO, NiOOH, Pb ₂ O ₄ , PbO ₂ , LiFePO ₄ , Li ₃ V ₂ (PO ₄ ) ₃ , V ₆ O ₁₃ , V ₂ O ₅ , Fe ₃ O ₄ , Fe ₂ O ₃ , MnO ₂ , LiCoO ₂ , LiNiO _An electrochemical cell is provided that includes a material selected from the group consisting of ₂ , LiMn ₂ O ₄ , LiVO ₂ , Li ₄ Ti ₅ O ₁₂ , TiO ₂ , WO ₂ , and MoO ₂ . In one embodiment, for example, the invention provides that the positive electrode is (i) a lithiated metal oxide based cathode selected from the group consisting of LixCoO ₂ , Li _x NiO ₂ , LixMn ₂ O ₄ , and LiFePO ₄ ; (Ii) selected from the group consisting of Ag _x V ₂ O ₅ , Cu _x V ₂ O ₅ , V ₂ O ₅ , V ₆ O ₁₃ , MnO ₂ , CuO, Ag ₂ CrO ₄ , and MoO ₃ , and x is 0 and non-lithiated metal oxide cathode which is in the range to _{2, and} the _{(iii) FeS 2, TiS 2} , FeS, and lithiated metal oxide cathode which is selected from the group consisting of CuS, (iv) elemental sulfur An active sulfur cathode selected from the group consisting of, polysulfides, and combinations thereof; and (v) an aqueous electrochemically active component such as water, or peroxide, water peroxide , O _2, SO _2, and NO ₂ or the like of gaseous, liquid, and solid oxidizing agent and a water-soluble oxidizing agent selected from the group consisting of a combination thereof, PEO / carbon / metal oxide The cathode structure and the water-soluble solid oxidant is selected from the group consisting of NaNO ₂ , KNO ₂ , Na ₂ SO ₃ , and K ₂ SO ₃ , and the conductive component of the cathode structure is a porous catalyst carrier such as nickel And the electrochemically active material of the cathode structure includes an air, PEO / carbon / metal oxide type cathode structure, and an electrochemical cell comprising a material selected from the group consisting of:

  The electrochemical cell of the present invention includes a primary electrochemical cell and a secondary electrochemical cell. In one embodiment, for example, the present invention provides a lithium battery, alkaline battery, zinc battery, lead acid battery, lithium metal-air battery, lithium ion battery, lithium air battery, Fe-air battery, Al-air battery, or zinc- An electrochemical cell including an air battery is provided. In one embodiment, for example, the invention provides an electrochemical cell comprising a fuel cell, a flow battery system, a semi-solid battery, a 3D battery, a nano battery, a micro battery, or an electrochemical capacitor. In one embodiment, for example, the present invention provides an electrochemical cell that includes a thin film battery. In one embodiment, for example, the present invention provides an electrochemical cell that is an alkali metal ion battery.

  In one embodiment, for example, the present invention provides a battery pack comprising one or more electrochemical cells, such as one or more lithium ion electrochemical cells. As will be appreciated by those skilled in the art, either the separator system or the electrochemical cell of the present invention may be used in the alkali metal fuel cell of the present invention.

  In one aspect, the present invention provides an alkali metal fuel cell comprising: (i) a renewable anode comprising a solid alkali metal and an alkali metal dissolved in a solvent as fuel; and (ii) a fixed electronically conductive component; An ion conductive component including an electrolyte for an alkali metal ion; and a cathode structure including a fluid oxidant obtained from the operating environment of the battery; and (iii) a separator system of the present invention disposed between the anode and the cathode structure. An alkali metal fuel cell is provided. As will be appreciated by those skilled in the art, any of the separator systems described herein may be used in the alkali metal fuel cells of the present invention.

  In one aspect, the present invention is a method of making an electrochemical cell comprising: (i) providing a negative electrode; (ii) providing a positive electrode; and (iii) between the positive and negative electrodes. And (iv) providing a separator system positioned between the positive electrode and the negative electrode, wherein the separator system is (i) a first high mechanical strength layer, and a first high mechanical strength. A first high mechanical strength layer having a plurality of openings provided in a first pattern penetrating the layer; and (ii) a second high mechanical strength layer, and penetrating the second high mechanical strength layer in a second pattern. The second pattern has a plurality of openings provided, and the second pattern includes openings of the first high mechanical strength layer and an second high mechanical strength layer along an axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer The first pattern is such that the overlap with the opening of 20% or less A second high mechanical strength layer having an offset arrangement, and the first high mechanical strength layer and the second high mechanical strength layer are provided in contact with the first high mechanical strength layer and the second high mechanical strength layer. Providing a separator system positioned so that ions of the electrolyte can be transported through the first high mechanical strength layer and the second high mechanical strength layer. In one embodiment, the separator system is at least partially in physical contact with the electrolyte. In one embodiment, the method further includes providing an ion conductive chemical barrier between the positive electrode and the negative electrode, the ion conductive chemical barrier contacting the first electrolyte in contact with the positive electrode with the negative electrode. The first electrolyte has a composition different from that of the second electrolyte, and the ion conductive chemical barrier prevents mixing of the first electrolyte and the second electrolyte. As is generally understood by those skilled in the art, any of the separator system and the system of the present invention that includes all the specific embodiments and combinations of components, materials, and properties described herein can be You may use with the method of producing a chemical cell.

  In one aspect, the present invention is a method for generating an electric current, the method comprising: (i) providing an electrochemical cell, wherein the electrochemical cell is (1) a first high mechanical strength layer; A first high mechanical strength layer having a plurality of openings provided in a first pattern penetrating the strength layer; and (2) a second high mechanical strength layer, the second pattern penetrating the second high mechanical strength layer. The second pattern includes openings of the first high mechanical strength layer and an axis of the second high mechanical strength along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. A second high mechanical strength layer having an offset arrangement with respect to the first pattern so that an overlap with an opening of the layer is 20% or less, and the first high mechanical strength layer and the second high mechanical strength layer are Electrolyte ions provided in contact with the first high mechanical strength layer and the second high mechanical strength layer are converted into the first high mechanical strength layer. And it is positioned so as to be transported through the second high mechanical strength layer, provides the steps of: providing an electrochemical cell, the method comprising the steps of discharging the (ii) an electrochemical cell. In one embodiment, the method of this aspect further comprises charging the electrochemical cell. In one embodiment, the method of this aspect further comprises the step of cycle charging the electrochemical cell with a plurality of charge and discharge cycles. As will be generally understood by those skilled in the art, the current separator system and the system of the present invention, including all specific embodiments and combinations of components, materials, and properties described herein, You may use by the method of generating.

  While not wishing to be bound by theory, it can be described herein for an overview or understanding of the basic principles or mechanisms for the present invention. Regardless of the final accuracy of the explanation or hypothesis, it is recognized that embodiments of the present invention are effective and useful.

A multi-layer separator system for an electrochemical system comprising parallel first high mechanical strength layers and second high mechanical strength layers having complementary opening patterns, wherein the second opening pattern is second from the first high mechanical strength layer. A side perspective view of a multi-layer separator system having an offset arrangement with respect to a first pattern such that there is no overlap between the opening of the first pattern and the opening of the second pattern along an axis extending vertically to the high mechanical strength layer is provided. . A multi-layer separator system for an electrochemical system comprising parallel first high mechanical strength layers and second high mechanical strength layers having complementary opening patterns, wherein the second opening pattern is second from the first high mechanical strength layer. There is a selection overlap between the opening of the first pattern and the opening of the second pattern along the axis extending vertically to the high mechanical strength layer, for example a selection overlap that minimizes or avoids dendrite growth in the separator system. FIG. 6 provides a side perspective view of a multilayer separator system having an offset arrangement relative to a first pattern. 1 provides a schematic diagram illustrating a cross-sectional view of a multilayer separator system of the present invention having a patterned first high mechanical strength layer and a second high mechanical strength layer separated by an electrolyte containing layer. 1 provides a schematic diagram illustrating a cross-sectional view of a multilayer separator system of the present invention having a patterned first high mechanical strength layer, a second high mechanical strength layer, and a third high mechanical strength layer separated by an electrolyte-containing layer. FIG. 3 provides a schematic diagram illustrating a cross-sectional view of the multilayer separator system of the present invention showing the orientation of the openings and solid regions of the first high mechanical strength layer and the second high mechanical strength layer separated by the electrolyte containing layer. Cross section of the multilayer separator system of the present invention showing the orientation of the openings and solid regions of the patterned first high mechanical strength layer, second high mechanical strength layer, and third high mechanical strength layer separated by the electrolyte containing layer 1 provides a schematic diagram illustrating the figure. FIG. 1 provides a schematic diagram providing a cross-sectional view of a lithium battery of the present invention comprising a separator system with two patterned high mechanical strength layers having complementary pattern openings. 1 provides a schematic diagram providing a cross-sectional view of a lithium battery of the present invention comprising a separator system with four patterned high mechanical strength layers having complementary pattern openings. FIG. 1 provides a schematic diagram providing a cross-sectional view of an electrochemical cell of the present invention comprising a separator system with three patterned high mechanical strength layers having complementary pattern openings. A separator system comprising a lithium metal anode, a cathode, three high mechanical strength layers having complementary opening patterns, two low ionic resistance layers, two electrolyte-containing voids, and a frame component. 1 provides a schematic diagram providing a cross-sectional view of an electrochemical cell. An electrochemical cell having a separator with a protective solid electrolyte (e.g. useful in Li-air batteries, Li-water batteries), where the solid electrolyte passes the desired ions (Li ^+, etc.) but water, air, 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impermeable to CO ₂ , contaminants, and materials that degrade the performance of the electrochemical cell. An electrochemical cell having a separator with a protective solid electrolyte (e.g. useful in Li-air batteries, Li-water batteries), where the solid electrolyte passes the desired ions (Li ^+, etc.) but water, air, 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impermeable to CO ₂ , contaminants, and materials that degrade the performance of the electrochemical cell. A cathode having a separator with a protective solid electrolyte (eg useful in Li-sulfur batteries), where the solid electrolyte passes the desired ions (Li ⁺ etc.) but reduces the performance of the electrochemical cell 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impervious to particle passage between the anode and the anode. An electrochemical cell having a separator, where the conductive side of the separator adjacent to the anode, for example, stops dendrite growth, reduces anode loss due to moss deposition, etc., and the cathode material moves to the anode during cycle charging and the anode A schematic is provided that provides a cross-sectional view of an electrochemical cell that reduces anode loss by preventing electronic contact between the particles and the current collector and degrading the performance of the electrochemical cell. An electrochemical cell having a separator, wherein a perforated separator plate and a porous layer provide electrical insulation between electrodes but provide ionic connection between electrodes via a fluid electrolyte (aqueous or aprotic) 1 provides a schematic diagram providing a cross-sectional view of an electrochemical cell that acts as a separator. FIG. An electrochemical cell having a separator, providing a schematic diagram that provides a cross-sectional view of the electrochemical cell, where the shape memory effect of the two high mechanical strength layers results in very good mechanical contact between the separator and the electrode To do. Provides an electrochemical cell having a separator, wherein the superelastic and / or shape memory effect of two high mechanical strength layers provides a very good mechanical contact between the separator and the electrode. A schematic diagram is provided. Provides an electrochemical cell having a separator, wherein the superelastic and / or shape memory effect of two high mechanical strength layers provides a very good mechanical contact between the separator and the electrode. A schematic diagram is provided. An electrochemical cell with a separator, where the conductive side of the separator breaks the electronic contact between the anode particles and the current collector, reducing the performance of the electrochemical cell, reducing anode loss due to large deformation of silicon during cycle charging, etc. And provides a schematic diagram providing a cross-sectional view of an electrochemical cell. In an electrochemical cell having a separator, the conductive side of the separator adjacent to the anode cuts the electronic contact between the anode particles and the current collector, thereby reducing the performance of the electrochemical cell, etc. 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that reduces anode loss. FIG. 11A provides examples of porous pattern layer designs for some separator systems of the present invention. 11B provides examples of porous pattern layer designs for some separator systems of the present invention. 1 shows a schematic diagram of a cross-sectional view of an electrochemical cell including a separator system of the present invention. 1 provides a schematic diagram illustrating potential trajectories of dendrite growth in an electrochemical system of the present invention. Panels A through M provide examples of complementary aperture patterns useful in the patterned high mechanical strength layer of the separator system of the present invention. Charge capacity and discharge capacity as a function of the cycle number of the electrochemical cell having (A) a multilayer separator system of the present invention having a total thickness of 125 microns and (B) a Celgard separator having a thickness of 25 microns (mAh / Provide a plot of g). (B, lines 2 and 3) (A, lines 1, 5, and 6) electrochemical with multilayer separator system of the present invention, Li metal anode, and LiCoO ₂ cathode compared to an electrochemical cell with a conventional separator. A plot of charge capacity and discharge capacity (mAh / g) as a function of cell cycle number is provided. (Lines F and D) Compared to a reference electrode made with a perforated kapton between two Celgard layers and (Lines H and I) a Celgard separator with a thickness of 25 microns (Lines A, B, and C) 3 provides a plot of charge capacity and discharge capacity (mAh / g) as a function of cycle number for an electrochemical cell having a multilayer separator system of the present invention, a Li metal anode, and a LiCoO ₂ cathode. FIG. 2 provides a schematic diagram illustrating an electrochemical cell of the present invention having a multilayer separator with three high mechanical strength layers having complementary opening patterns. 19 provides a schematic diagram illustrating the trajectory of Li ⁺ ions passing through the multilayer separator shown in FIG. 7 provides a plot of cell voltage (V vs. Li) against cycle time (hours) for constant current lithium stripping from two symmetrical (5/9) inch lithium chips. Provide plots of current [mA] versus time [hours] and voltage [v] versus time [hours]. FIG. 6 provides plots of current [A] (top) and voltage [v] (bottom) as a function of time [seconds] in CR2032 cells made with Li-metal, LiFePO ₄ cathode. 1 provides a photograph of a porous layer useful in one embodiment of a separator system. 1 provides a photograph of a porous layer useful in one embodiment of a separator system. 1 provides a photograph of a perforated layer useful in one embodiment of a separator. 1 provides a photograph of a perforated layer useful in one embodiment of a separator. 1 provides a photograph of a perforated layer useful in one embodiment of a separator. 1 provides a photograph of a perforated layer useful in one embodiment of a separator. 1 provides a photograph of a perforated layer useful in one embodiment of a separator. 1 provides a photograph of a perforated layer useful in one embodiment of a separator.

  In general, the terms and phrases used herein have art-recognized meanings that can be viewed with reference to standard textbooks, journal literature, and context known to those skilled in the art. The following definitions are provided to clarify specific applications for the present invention.

  Referring to the drawings, like numerals indicate like elements and the same number appearing in more than one figure refers to the same element. In addition, the following definitions apply below.

  The term “electrochemical cell” refers to a device and / or device component that converts chemical energy into electrical energy or electrical energy into chemical energy. An electrochemical cell has two or more electrodes (eg, positive and negative electrodes) and an electrolyte, and the electrode reaction that occurs at the electrode surface results in a charge transfer process. Electrochemical cells include, but are not limited to, primary batteries, secondary batteries, and electrolysis systems. In certain embodiments, the term electrochemical cell includes fuel cells, supercapacitors, capacitors, flow batteries, metal-air batteries, and semi-solid batteries. Common cell and / or battery configurations are known in the art, such as US Pat. Nos. 6,489,055, 4,052,539, 6,306,540, Seel and Dahn. J. et al. Electrochem. Soc. 147 (3) 892-898 (2000).

The term “capacity” is a characteristic of an electrochemical cell that refers to the total amount of charge that an electrochemical cell such as a battery can hold. Capacity is usually expressed in units of ampere hours. The term “specific capacity” refers to the capacity output of an electrochemical cell such as a battery per unit weight. Specific capacity is usually expressed in units of kg- ¹ ampere-hours.

  The term “discharge rate” relates to the current at which the electrochemical cell is discharged. The discharge rate can be expressed in amperes. Alternatively, the discharge rate can be normalized to the rated capacity of the electrochemical cell and expressed as C / (Xt), where C is the capacity of the electrochemical cell, X is a variable, and t is As used herein, a specified time unit equal to one hour.

  “Current density” refers to the current flowing per unit electrode area.

  An electrode refers to a conductor that exchanges ions and electrons with an electrolyte and an external circuit. “Positive electrode” and “cathode” are used interchangeably herein and refer to an electrode having a high electrode potential (ie, higher than a negative electrode) in an electrochemical cell. “Negative electrode” and “anode” are used interchangeably herein and refer to an electrode having a low electrode potential (ie, lower than a positive electrode) in an electrochemical cell. Cathodic reduction refers to the acquisition of electron (s) of a chemical species, and anodic oxidation refers to the loss of electron (s) of a chemical species. The positive electrode and the negative electrode of the electrochemical cell may further include a conductive diluent such as acetylene black, carbon black, powdered graphite, coke, carbon fiber, graphene, and metal powder, and / or a polymer binder. Etc. can be further provided. Binders useful for the positive electrode in some embodiments include fluoropolymers such as polyvinyl fluoride (PVDF). The positive and negative electrodes of the present invention can be provided in a range of useful configurations and form factors known in the fields of electrochemical and battery science, including thin electrode designs such as thin film electrode configurations. . The electrodes are disclosed, for example, in US Pat. Nos. 4.052,539, 6.306,540, and 6.852,446 as disclosed herein and known in the art. Manufactured as is. In some embodiments, the electrode comprises depositing a slurry of electrode material, a conductive inert material, a binder, and a liquid carrier on the electrode current collector and then evaporating the carrier to form a dense body with the current collector. It is usually made by electrical contact.

  “Electrode potential” refers to the voltage normally measured for this electrode due to the presence of a chemical species in or in contact with the reference electrode in various oxidation (valence) states.

  “Electrolyte” refers to an ionic conductor that can be in the solid state, the liquid state (most common), or less frequently a gas (eg, a plasma).

  “Standard electrode potential” (E °) refers to the electrode potential when the solute concentration is 1 M, the gas pressure is 1 atm, and the temperature is 25 ° C. As used herein, standard electrode potential is measured against a standard hydrogen electrode.

  “Active material” refers to a material in an electrode that participates in an electrochemical reaction that stores and / or transmits energy to an electrochemical cell.

  “Cation” refers to positively charged ions, and “anion” refers to negatively charged ions.

  “Electrical contact” and “electrical communication” refer to an arrangement of one or more objects such that current flows efficiently from object to object. For example, in some embodiments, two objects that have an electrical resistance between them of less than 100Ω are considered to be in electrical communication with each other. Electrical contact can also refer to components of a device or object used to establish electrical communication, eg, electrical interconnections, with external devices or circuits. “Electric communication” refers to the ability of two or more materials and / or structures that are capable of charge transfer between each other, such as in the form of electron transfer. In some embodiments, the components in electrical communication are in direct electrical communication and electronic signals or charge carriers are transferred directly from component to component. In some embodiments, the components in electrical communication are in indirect electrical communication, and the electronic signal or charge carrier is component-to-component via one or more intermediate structures such as circuit elements that separate the components. Indirectly transferred to

  “Thermal contact” and “thermal communication” are used synonymously and are two elements than if the elements or materials such as current collector or heat transfer rod and heat sink or heat source are thermally separated or thermally insulated. Refers to their orientation or position such that heat is efficiently transferred between them. An element or material is considered to be in thermal communication or contact when heat is transferred between them more rapidly than if it were thermally separated or thermally insulated. Two elements in thermal communication or contact can reach thermal equilibrium or thermal steady state, and in some embodiments can always be considered to be in thermal equilibrium or thermal steady state with respect to each other. In some embodiments, elements in thermal communication with each other are separated from each other by a heat conducting material or an intermediate heat conducting material or device component. In some embodiments, the elements in thermal communication with each other are separated by a distance of 1 μm or less. In some embodiments, the elements in thermal communication with each other are provided in physical contact.

  “High mechanical strength” refers to a first high mechanical strength that is sufficient to prevent dendrite growth between the positive and negative electrodes of the electrochemical cell, for example during a charge / discharge cycle of a secondary electrochemical cell. It refers to the characteristics of the components of the separator system of the present invention, such as a mechanical strength layer, a second high mechanical strength layer, a third high mechanical strength layer, and a fourth high mechanical strength layer. In one embodiment, for example, the high mechanical strength layer has sufficient mechanical strength to prevent penetration due to dendrite growth between the electrodes. In one embodiment, for example, the high mechanical strength layer has sufficient mechanical strength to prevent a short circuit between the electrodes due to dendrite growth between the positive and negative electrodes of the electrochemical cell. In one embodiment, for example, the high mechanical strength layer has a Young's modulus of 500 MPa or more, in some cases a Young's modulus of 1 GPa or more in some applications, and in some cases a Young's modulus of 10 GPa or more, in some cases. It is characterized by a Young's modulus of 100 GPa or more in some applications. In one embodiment, for example, the high mechanical strength layer has a yield strength of 5 MPa or more, in some cases a yield strength of 50 MPa or more, and in some cases a yield strength of 100 MPa or more, in some cases. Characterized by yield strength of 500 MPa or more in some applications. In one embodiment, for example, the high mechanical strength layer has a tear strength of 0.005 N or greater, and in some applications, a tear strength of 0.05 N or greater, a tear strength of 0.5 N or greater, and a tear strength of 1 N or greater. It is characterized by. In one embodiment, for example, the high mechanical strength layer is characterized by an initial tear strength of 10 N or higher, and possibly an initial tear strength of 100 or higher in some applications. In one embodiment, for example, the high mechanical strength layer has a tensile strength of 50 MPa or more, in some cases a tensile strength of 100 MPa or more in some applications, and in some cases a tensile strength of 500 MPa or more, in some cases. It is characterized by a tensile strength of 1 GPa or more in some applications. In one embodiment, for example, the high mechanical strength layer has an impact strength of 10 Ncm or more, in some cases an impact strength of 50 Ncm or more in some applications, in some cases an impact strength of 100 Ncm or more in some applications, It is characterized by an impact strength of 500 Ncm or more.

  “Chemical resistance” refers to the property of a component, such as a separator and a layer of an electrochemical system of the present invention, that has a tensile retention and elongation retention of at least 90% in the operating environment of an electrochemical system such as an electrochemical cell. .

  “Thermal stability” is a separator and electrochemical system of the invention having a melting point above 100 ° C., preferably in some embodiments above 300 ° C., and in some cases with a coefficient of thermal expansion of less than 50 ppm / ° C. Refers to the characteristics of a component such as a layer. In one embodiment, “thermally stable” is a component of a separator system that can be implemented in a rechargeable electrochemical cell without causing a change in size or shape with a temperature that significantly reduces the performance of the electrochemical cell. Refers to characteristics.

  “Porosity” refers to the amount of a material or component, such as a high mechanical strength layer, that corresponds to pores such as openings, channels, voids and the like. Porosity can be expressed as the ratio of the volume of a material, structure, or device component corresponding to a hole such as a hole, channel, or void to the total volume occupied by the material, structure, or device component such as a high mechanical strength layer. .

  FIG. 1 is a multilayer separator system 100 (1) for an electrochemical system comprising parallel first high mechanical strength layers and second high mechanical strength layers having complementary opening patterns, wherein the second opening patterns are A multilayer separator having an offset arrangement with respect to the first pattern so that there is no overlap between the opening of the first pattern and the opening of the second pattern along an axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer 1 provides a side perspective view of system 100 (1). FIG. As shown in FIG. 1, a multilayer separator system 100 (1) includes a first high mechanical strength layer 102 (1) having a first pattern with a plurality of openings, eg, 104 (1) and 104 (4); A second high mechanical strength layer 102 (2) having a second pattern with a second plurality of openings, eg 104 (2) and 104 (3). The first and second layers are characterized by a planar geometric shape and lateral dimensions such as height H, length L, and width or thickness W. As shown in FIG. 1, the opening 104 penetrates the thickness of the first high mechanical strength layer 102 (1) or the second high mechanical strength layer 102 (2). Each opening 104 is also characterized by a lateral dimension such as a height h, a length l, and a width or thickness (not shown).

  The pattern overlap of the first high mechanical strength layer 102 (1) on the second high mechanical strength layer 102 (2) is formed as a plurality of offset broken line areas 106 (1) on the second high mechanical strength layer 102 (2). The overlay of the second high mechanical strength layer 102 (2) on the first high mechanical strength layer 102 (1) is schematically represented by a plurality of offset dashed line areas 106 ( 2) is schematically represented. In the embodiment shown in FIG. 1, the first pattern and the second pattern are similar to a checker board. For example, the first pattern corresponds to a black square and the second pattern corresponds to a red square of the checker board. However, as will be apparent to those skilled in the art, the first pattern and the second pattern have an offset arrangement with respect to each other, for example, from the first high mechanical strength layer 102 (1) to the second high mechanical strength layer 102. As long as the overlap of openings 104 along the axis extending vertically to (2) is no more than 50%, 40%, 30%, 20%, 10%, 5%, 2%, or 0%, the honeycomb pattern, close-packed Other patterns such as a circular pattern, a brick pattern, a triangular pattern are also possible. In the embodiment shown in FIG. 1, there is no overlap between the opening of the first pattern and the opening of the second pattern along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer. The arrows 108 (1) and 108 (2) shown in FIG. 1 indicate openings that do not overlap along an axis extending perpendicularly from the first high mechanical strength layer 102 (1) to the second high mechanical strength layer 102 (2). An offset arrangement of the first opening pattern of the first high mechanical strength layer and the second opening pattern of the second high mechanical strength layer is provided, for example, to mechanically block the growing dendrite and / or Preventing dendrite growth through the combination of the first high mechanical strength layer and the second high mechanical strength layer by requiring a path with a thermodynamically and / or kinetically unfavorable curved trajectory. Since the dendrite is physically blocked by the first high mechanical strength layer 102 (1) at the point 110 (1), the opening 104 (3) of the second high mechanical strength layer 102 (2) is opened as indicated by an arrow A. Only to pass Similarly, the dendrite is physically blocked by the second high mechanical strength layer 102 (2) at point 110 (2), so that the opening of the first high mechanical strength layer 102 (1) is indicated by arrow B. 104 (4) can only be passed.

  FIG. 2 is a multilayer separator system 100 (2) for an electrochemical system with parallel first high mechanical strength layers and second high mechanical strength layers having complementary opening patterns, the second opening pattern being An offset arrangement is made with respect to the first pattern so that there is an overlap of a selection range between the opening of the first pattern and the opening of the second pattern along the axis extending vertically from the first high mechanical strength layer to the second high mechanical strength layer. A side perspective view of a multilayer separator system 100 (2) having is provided. As shown in FIG. 2, the multilayer separator system 100 (2) includes a first high mechanical strength layer 102 (3) having a first pattern with a plurality of openings, eg, 104 (5) and 104 (9); A second high mechanical strength layer 102 (4) having a second pattern with a second plurality of openings, eg 104 (6), 104 (7), and 104 (8). The first high mechanical strength layer and the second high mechanical strength layer 102 are characterized by a lateral dimension such as a height H, a length L, and a width or thickness W. As shown in FIG. 2, the opening 104 penetrates the thickness of the first high mechanical strength layer 102 (3) and the second high mechanical strength layer 102 (4). Each opening 104 is also characterized by a lateral dimension such as a height h, a length l, and a width or thickness (not shown).

  Overlaying the pattern of the first high mechanical strength layer 102 (3) on the second high mechanical strength layer 102 (4) as a plurality of offset broken line areas 106 (3) on the second high mechanical strength layer 102 (4) The overlay of the second high mechanical strength layer 102 (4) on the first high mechanical strength layer 102 (3) is schematically represented by a plurality of offset dashed areas 106 ( 4) schematically. In the embodiment shown in FIG. 2, the first and second patterns are a selection of openings 104 along an axis extending perpendicularly from the first high mechanical strength layer 102 (3) to the second high mechanical strength layer 102 (4). Having an offset array relative to each other such that there is a overlap. In one embodiment, for example, the selected overlap is 50%, 40%, 30%, 20%, 10%, 5%, or 2% or less. In the embodiment shown in FIG. 2, the overlap between the first pattern opening and the second pattern opening along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer is greater than zero. The arrows shown in FIG. 2 indicate the overlapping region 112 of the opening and the region of the opening that does not overlap along the axis extending perpendicularly from the first high mechanical strength layer 102 (3) to the second high mechanical strength layer 102 (4). Provided to show. The offset arrangement of the opening pattern of the first high mechanical strength layer and the opening pattern of the second high mechanical strength layer, for example, involves dendrite growth and / or with a thermodynamically and / or kinetically disadvantageous curved trajectory. The need for a path prevents dendrite growth through the combination of the first high mechanical strength layer and the second high mechanical strength layer.

  The invention can be further understood by the following non-limiting examples.

New separators for electrochemical systems such as batteries, rechargeable lithium batteries, and chemical systems, especially for preventing dendrite short-circuits in Li-metal batteries . FIG. 3 shows complementary layers separated by an electrolyte-containing layer (layer M). FIG. 2 provides a schematic diagram illustrating a cross-sectional view of a multilayer separator system of the present invention having a first high mechanical strength layer and a second high mechanical strength layer (Layer R and Layer F) having a variable opening pattern. FIG. 4 shows a multilayer separator system of the present invention having a first high mechanical strength layer, a second high mechanical strength layer, and a third high mechanical strength layer (layers R and F) separated by an electrolyte containing layer (layer M). 1 provides a schematic diagram illustrating a cross-sectional view of 3 and 4, the layers (R) and (F) have a high opening pattern that prevents dendrite growth in the separator system when provided in combination when incorporated in an electrochemical system such as an electrochemical cell. It is a mechanical strength layer. 3 and 4, the electrolyte-containing layer (s) M is provided between the layers F and R, and in some embodiments, the electrolyte-containing layer (s) M is more than the layers F and R. It is also preferable that the thickness is thick. In an electrochemical system, for example, the layer (s) M acts as an electrolyte reservoir. In an electrochemical system, for example, the layer (s) M acts as a separator, thereby preventing electrical and / or physical contact between the positive and negative electrodes and between the positive and negative electrodes. Ion transport, and the electrochemical cell can obtain efficient charge / discharge characteristics. In one embodiment, for example, layer M is a low ionic resistance layer such as a conductive microporous membrane. In one embodiment, for example, layer M is a polyethylene (PE) film or a polypropylene (PP) film or a combination of both.

  In some embodiments, the high mechanical strength layers F and R function to prevent dendrite growth in the cell, such as preventing electrical shorts, thermal runaway, and / or mechanical failure of the electrochemical cell. As an example, the high mechanical strength layers F and R may be configured to prevent short circuit and capacity loss of lithium metal batteries by preventing dendrite growth between the positive and negative electrodes. In some embodiments, high mechanical strength layers F and R provide complementary barriers, each of which is sufficient to prevent barrier penetration or mechanical failure when in contact with growing dendrites. Has mechanical strength.

  In some embodiments, high mechanical strength layers F and R are provided with complementary opening patterns that penetrate the entire thickness of the layer. FIG. 5 shows an opening (schematically shown as a stippled region) and a solid of a first high mechanical strength layer and a second high mechanical strength layer separated by one or more low ion resistance layers, such as electrolyte-containing layer M FIG. 2 provides a schematic diagram illustrating a cross-sectional view of the multilayer separator system of the present invention showing regions (shown schematically as filled regions). FIG. 6 shows openings and solid regions of the first high mechanical strength layer, the second high mechanical strength layer, and the third high mechanical strength layer separated by one or more low ion resistance layers such as the electrolyte-containing layer M. FIG. 1 provides a schematic diagram illustrating a cross-sectional view of the multilayer separator system of the present invention. By way of example, the high mechanical strength layer (s) F is characterized by a preselected first opening pattern and solid area, and the high mechanical strength layer (s) R is of the high mechanical strength layer F. May be characterized by a preselected second opening pattern and solid region different from. In one embodiment, for example, the two patterns are complementary, and each of the high mechanical strength layers F and R has openings (eg, through holes, holes) that allow transport of ions and electrolytes from both sides of the high mechanical strength layer. The arrangement of the high mechanical strength layers F and R in the geometry of the multi-layer separator system is for example from the high mechanical strength layer (s) R to the high mechanical strength layer The aperture of the high mechanical strength layer F is made to coincide with the solid region of the high mechanical strength layer R along the axis extending vertically to F (s), and the solid region of the high mechanical strength layer F is made to be the high mechanical strength layer. Match with R holes. In one embodiment, for example, the openings in the high mechanical strength layers F and R are straight through the holes in both layers F and R when the layers F and R are combined, eg provided in parallel or concentric orientation. Offset relative to each other so that they cannot. This spatial arrangement can be visualized, for example, by considering a periodic pattern such as a chessboard having white and black squares, where the white squares correspond to openings and the black squares are solid areas of the high mechanical strength layer. It corresponds to. In one example, the high mechanical strength layer F can be in the form of a normal chess board, with the high mechanical strength layer R reversed and the white block (corresponding to the opening) in the black square (solid portion of the layer F). There is a false chessboard type with black blocks (corresponding to solid areas) instead of white squares (holes in layer F). This offset arrangement results in at least two high mechanical strength layers where all holes are obstructed by solid regions of the adjacent layer when provided in a multi-layer geometry.

  Placing a low ionic resistance layer M (ordinary separator) between the high mechanical strength layers F and R provides a separator system that prevents unwanted dendrite growth through the separator system. However, in order to minimize the effect of the separator system on cell resistance, in some embodiments, at least maintaining the thickness necessary to provide sufficient mechanical strength to block the growing dendrite. It is desirable to minimize the thickness of the high mechanical strength layers F and R.

  In one embodiment, for example, the high mechanical strength layers F and R are very thin (eg, 100 μm or less, and in some embodiments 20 μm or less in some embodiments), and thus in some cases the front side of layer M and It may be in the form of one or more coatings on the rear surface. The volume fraction and surface fraction of the pores of the high mechanical strength layers F and R are selected for a given application, and in some applications at least 1/4 of the surface-volume, optionally half includes openings, It is preferred that the remainder include an impermeable solid region. In one embodiment, the high mechanical strength layers F and R comprise a chemically resistant and thermally stable material that does not react with other components of the electrochemical cell. In one embodiment, the high mechanical strength layers F and R include an electrical insulator.

  In certain embodiments useful for lithium-metal batteries, the high mechanical strength layers F and R allow the passage of ions and electrolytes but prevent the direct passage of current between the positive and negative electrodes of the electrochemical cell. A polyethylene film or polypropylene film or Teflon or a mixture of these materials having a complementary opening pattern. In one embodiment, for example, the low ionic resistance layer M is a porous polyethylene film or a porous polypropylene film or a mixture thereof. In one embodiment, the low ionic resistance layer M is selected from the range of 10 micrometers to 200 micrometers, and preferably has a thickness equal to 80 micrometers to 120 micrometers for some applications, The strength layers F and R are each independently selected from the range of 5 micrometers to 200 micrometers, and preferably have a thickness equal to 10 micrometers to 30 micrometers for some applications. In one embodiment, the high mechanical strength layers L and M have complementary periodic opening patterns and solid regions, and one or more lateral dimensions of the unit cell characterizing the openings and / or solid regions are, for example, It is selected in the range of 1 micrometer to 1 millimeter, preferably 10 micrometers to 30 micrometers for some applications. Although it is preferred in some embodiments that the size of the lateral dimension of the unit cell of the opening is smaller and only as large as 10 times the average opening size of the layer M, a large opening has practical advantages for fabrication. It will be appreciated that there may be a compromise in choosing the physical dimensions of the aperture.

  As will be apparent to those skilled in the art, the composition, physical dimensions (eg, thickness), and mechanical properties (eg, porosity) of the components of the separator system depend on the type and / or application of the electrochemical or chemical cell. Can vary depending on In one embodiment, for example, a separator system for a lead acid battery may use a thicker high mechanical strength layer having a larger pore size than a separator system for a lithium-metal battery.

  In addition to the R-MF and F-MR-MF systems shown in FIGS. 3 and 5, other separator geometries are useful in some applications. By way of example, the present invention includes a multilayer system with three, four, five, six, seven, eight, etc. high mechanical strength layers having an opening pattern selected to prevent dendrite growth. . Multi-layer systems with three or more high mechanical strength layers, such as those corresponding to the F-M-R-M-F system shown in FIGS. 4 and 6, are preferred for some applications, because they are positive. Even though it can be configured to efficiently prevent dendrite growth from electrode to negative electrode, the added resistance to the cell can remain low enough to provide useful charge / discharge performance. is there.

  By way of example, a high energy rechargeable lithium battery of the invention comprises (1) an anode comprising lithium metal or lithium alloy, or a mixture of lithium metal and / or lithium alloy and another material, (2) a cathode, (3 And) a separator system of the present invention disposed between the anode and the cathode; and (4) one or more electrolytes that are in ionic communication with the anode and the cathode and possibly in physical contact via the separator. In one embodiment, for example, the electrolyte is a solid, a gel, or a liquid (eg, a fluid). In some embodiments, the electrode is a solid material or semi-solid particles (eg, small solid particles in a liquid) such as those used in semi-solid batteries or flow batteries or flow cells. The cross-sectional geometry of the separator system can be a range of shapes including rectangular, circular, square, and the like.

  FIG. 7 provides a schematic diagram that provides a cross-sectional view of a lithium battery of the present invention with a separator system with two high mechanical strength layers having complementary pattern openings. The electrochemical cell comprises an anode (eg, lithium metal) and a cathode separated by a multi-layer separator system that includes an electrolyte reservoir. The multilayer separator comprises two high mechanical strength layers having complementary opening patterns separated by low ion resistance layers such as electrolyte containing separators and / or spacers. Furthermore, a very porous medium is provided between the high mechanical strength layer and the anode and cathode components. As shown in FIG. 7, the high mechanical strength layer has a pattern including alternating openings and solid regions (for example, in FIG. 7, the filled region corresponds to the solid region of the high mechanical strength layer, and the stipple region is Equivalent to an opening through the high mechanical strength layer). In the illustrated embodiment, the high mechanical strength layer has a complementary opening pattern that can prevent dendrite growth between the cathode and the anode, as shown in FIG. The open area (eg, opening) corresponds to the solid area of the second high mechanical strength layer along an axis extending perpendicularly from the layer.

  8-10 provide examples of other embodiments of lithium batteries showing still other device configurations and device components of the present invention. FIG. 8 provides a schematic diagram that provides a cross-sectional view of the lithium battery of the present invention with a separator system with four high mechanical strength layers having complementary pattern openings. In the apparatus shown in FIG. 8, the high mechanical strength layer R is provided in direct physical contact with the anode, and the high mechanical strength layer F is provided in direct physical contact with the cathode. In the embodiment shown in FIG. 8, the two layers R have the same opening pattern and the two layers F have the same opening pattern. Both patterns of layers R and F include complementary patterns that prevent dendritic growth related shorts by eliminating a direct linear path between the anode and cathode along an axis extending vertically from the cathode to the anode. In the embodiment shown in FIG. 8, a high mechanical strength layer R is provided in physical contact with the anode so that ions pass through the layer R and interact with the anode surface, and the high mechanical strength layer F is provided with ions. Provided in physical contact with the cathode to pass through layer F and interact with the cathode surface.

  FIG. 9 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell of the present invention comprising a separator system with three high mechanical strength layers having complementary pattern openings. In the apparatus shown in FIG. 9, a very porous layer (for example, porosity ≧ 80%) is provided between the high mechanical strength layer F and the anode, and a very porous layer (for example, porosity ≧ 80%) is provided. Is provided between the high mechanical strength layer F and the cathode. In the apparatus shown in FIG. 9, the high mechanical strength layer R has an opening pattern complementary to the opening pattern of the high mechanical strength layer F, and the porous layer (for example, porosity ≧ 50%) is replaced with the high mechanical strength layer R. And a high mechanical strength layer F. In one embodiment, for example, the two high mechanical strength layers F are characterized by the same opening pattern. In the embodiment shown in FIG. 9, the two layers F have the same opening pattern. The patterns in layer R and two layers F together are complementary patterns that prevent dendritic growth related short circuits by eliminating a direct linear path between the anode and cathode along an axis extending vertically from the cathode to the anode. including. In the embodiment shown in FIG. 9, a very porous layer (eg, porosity ≧ 80%) is in physical contact with the anode surface so that ions pass through the porous layer and interact with the anode surface. A very porous layer (eg, porosity ≧ 80%) is provided in physical contact with the cathode surface so that ions pass through the porous layer and interact with the cathode surface.

  FIG. 10A comprises a lithium metal anode, a cathode, and a separator system with three high mechanical strength layers with complementary opening patterns, two low ionic resistance layers, two electrolyte containing voids, and a frame component. 1 provides a schematic diagram providing a cross-sectional view of the electrochemical cell of the present invention. In some embodiments, for example, the frame layer (s) provide a means to physically integrate, attach, and / or mechanically support the components of the entire multilayer construction. In the lithium battery shown in FIG. 10, an electrolyte-containing void is provided between the anode and the first high mechanical strength layer having the opening pattern, and the electrolyte-containing void is provided between the cathode and the second high mechanical strength layer having the opening pattern. Provide. In some embodiments, for example, the incorporation of an electrolyte-containing void between the electrode and the high mechanical strength layer is useful to avoid reducing electrode surface area to take advantage of the useful charge / discharge characteristics of the cell. is there. In the apparatus shown in FIG. 10A, the high mechanical strength layer R has an opening pattern complementary to the opening pattern of the high mechanical strength layer F, and the low ion resistance layer (for example, porosity ≧ 50%) is used as the high mechanical strength layer. It is provided between R and the high mechanical strength layer F.

FIG. 10B is an electrochemical cell having a separator with a protective solid electrolyte (eg useful in Li-air batteries, Li-water batteries), where the solid electrolyte passes the desired ions (Li ⁺ etc.). 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impermeable to water, air, CO ₂ , contaminants, and materials that degrade the performance of the electrochemical cell. The electrochemical cell includes an anode such as a lithium anode, a cathode such as a carbon-water cathode or a carbon-air cathode, two high mechanical strength layers having complementary opening patterns, three low ion resistance layers, and a LISICON layer. And a separator system including the solid electrolyte layer. In the apparatus shown in FIG. 10B, the high mechanical strength layer is an optionally chemically resistant and thermally stable porous layer that is also electrically insulating, such as a porous Kapton layer. The use of a complementary high mechanical strength layer comprising kapton is useful in some embodiments to prevent dendrite growth. As shown in FIG. 10B, a first low ionic resistance layer such as a very porous layer (eg, ≧ 80%) is provided between the anode and the first high mechanical strength layer to form a very porous layer ( For example, a second low ionic resistance layer such as ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer, and a second layer such as a very porous layer (for example, ≧ 80%) is provided. 3 A low ionic resistance layer is provided between the second high mechanical strength layer and the cathode. As shown in FIG. 10B, a solid electrolyte layer such as a LISICON layer is provided between the third low ion resistance layer and the cathode so that ions can be transported to the cathode surface. In one embodiment, for example, the solid electrolyte layer is provided in physical contact with the surface of the cathode. In some embodiments, the incorporation of a solid electrolyte layer (e.g., a LISICON layer) can protect the cathode, e.g., from unwanted chemical reactions with components of the electrochemical cell such as the cathode surface and electrolyte components other than the solid electrolyte. Useful for protection. In some embodiments, the solid electrolyte layer (e.g., the LISICON layer) is disposed on the first side of the electrochemical cell having the first electrolyte from the second side of the electrochemical cell having a second electrolyte different from the first electrolyte. A chemical barrier layer is provided for separation. Thus, embodiments of this aspect may provide a means of integrating two separate electrolytes, each tailored specifically to the selected anode and cathode compositions.

FIG. 10C is an electrochemical cell having a separator with a protective solid electrolyte (eg useful in Li-air batteries, Li-water batteries), where the solid electrolyte passes the desired ions (Li ⁺ etc.). 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impermeable to water, air, CO ₂ , contaminants, and materials that degrade the performance of the electrochemical cell. The electrochemical cell comprises a solid electrolyte such as a lithium anode, a cathode such as a carbon-water cathode or a carbon-air cathode, two high mechanical strength layers with complementary opening patterns, three low ionic resistance layers, and a LISICON layer. A separator system with a layer. The overall geometry of the electrochemical cell in FIG. 10C is similar to that shown in FIG. 10B, with a first low ionic resistance layer such as a very porous layer (eg, ≧ 80%) as the anode. A second low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer. And a third low ion resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the second high mechanical strength layer and the cathode, and a solid electrolyte layer such as a LISICON layer is provided at the third low layer. It is provided between the ion resistance layer and the cathode so that ions can be transported to the cathode surface. However, in the electrochemical cell of FIG. 10, the high mechanical strength layer is a perforated metal having a complementary opening pattern that in some embodiments is useful for preventing dendrite growth and reducing anode loss, such as mossy deposition. Is a layer. Similar to the description associated with FIG. 10B, the incorporation of a solid electrolyte layer (eg, a LISCON layer) can result in cathode protection, for example, undesirable chemistry with components of the electrochemical cell such as the cathode surface and electrolyte components other than the solid electrolyte. Useful for protection from reactions. In some embodiments, the solid electrolyte layer (e.g., the LISICON layer) is disposed on the first side of the electrochemical cell having the first electrolyte from the second side of the electrochemical cell having a second electrolyte different from the first electrolyte. A separate chemical barrier layer may be provided, thus providing a means of integrating two separate electrolytes, each tailored specifically to the selected anode and cathode compositions.

FIG. 10D is an electrochemical cell having a separator with a protective solid electrolyte (eg, useful in Li-sulfur batteries), where the solid electrolyte passes the desired ions (such as Li ⁺ ) but the performance of the electrochemical cell. FIG. 6 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that is impermeable to particle passage between the cathode and anode to reduce the aging. The electrochemical cell includes an anode such as a lithium anode, a cathode such as a sulfur-based cathode, two high mechanical strength layers having complementary opening patterns, three low ion resistance layers, and a solid electrolyte layer such as a LISICON layer. Separator system. The overall geometry of the electrochemical cell in FIG. 10D is similar to that shown in FIGS. 10B and 10C, and a first low ionic resistance layer, such as a very porous layer (eg, ≧ 80%) Is provided between the anode and the first high mechanical strength layer, and a second low ion resistance layer such as a very porous layer (for example, ≧ 80%) is provided as the first high mechanical strength layer and the second high mechanical strength layer. A third low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the second high mechanical strength layer and the cathode, and a solid electrolyte layer such as a LISICON layer is provided. It is provided between the third low ion resistance layer and the cathode so that ions can be transported to the cathode surface. However, in the electrochemical cell of FIG. 10D, the high mechanical strength layer is a perforated metal layer with a complementary opening pattern, and the cathode is optionally a sulfur-based cathode. Incorporation of a high mechanical strength layer into the separator is useful in some embodiments to prevent dendrite growth, reduce anode loss, such as mossy deposition, and stop the migration of cathode material to the anode. Similar to the description associated with FIG. 10B, the incorporation of a solid electrolyte layer (eg, a LISCON layer) can result in cathode protection, for example, undesirable chemistry with components of the electrochemical cell such as the cathode surface and electrolyte components other than the solid electrolyte. Useful for protection from reactions. In some embodiments, the solid electrolyte layer (e.g., the LISICON layer) is disposed on the first side of the electrochemical cell having the first electrolyte from the second side of the electrochemical cell having a second electrolyte different from the first electrolyte. A separate chemical barrier layer may be provided, thus providing a means of integrating two separate electrolytes, each tailored specifically to the selected anode and cathode compositions.

FIG. 10E shows an electrochemical cell having a separator, where the conductive side of the separator adjacent to the anode, for example, stops dendrite growth, reduces anode loss due to moss deposition, etc., and the cathode material is the anode during cycle charging. Provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that reduces anode loss by preventing the electronic contact between the anode particles and the current collector and degrading the performance of the electrochemical cell by moving to To do. For example, the conductive side adjacent to the cathode increases the conductivity of the cathode, resulting in a longer life cycle, greater power and thicker cathode, and a higher energy cathode, and thus a better electrochemical cell. The electrochemical cell includes an anode such as a lithium anode, a cathode such as LiFePO ₄ and LiCoO ₂ cathodes, two high mechanical strength layers having complementary opening patterns, three low ion resistance layers, and a carbon black layer. And a separator system with a resistive, chemical resistant, and heat resistant ion conductive layer. The overall geometry of the electrochemical cell in FIG. 10E is similar to that shown in FIGS. 10B, 10C, and 10D, with a first such as a very porous layer (eg, ≧ 80%). A low ionic resistance layer is provided between the anode and the first high mechanical strength layer, and a second low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), is provided between the first high mechanical strength layer and the second high mechanical strength layer. A third low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the second high mechanical strength layer and the cathode. However, in the electrochemical cell of FIG. 10E, the first high mechanical strength layer includes a perforated metal layer and the second high mechanical strength layer includes a perforated electrical insulating layer such as a perforated kapton layer. In this embodiment, the perforated metal layer and the perforated kapton layer have complementary opening patterns to prevent dendrite growth. Furthermore, a mechanical, chemical and heat resistant ion conductive carbon black layer is provided adjacent to the cathode, and possibly in electrical and / or physical contact with the cathode.

FIG. 10F is an electrochemical cell with a separator, where the perforated separator plate and porous layer provide electrical insulation between the electrodes but provide ionic connections between the electrodes via a fluid electrolyte (aqueous or aprotic). A schematic is provided that provides a cross-sectional view of an electrochemical cell that serves as a separator by providing. The electrochemical cell has two high mechanical strengths with complementary opening patterns, such as an anode such as a silicon, Li, Zn, ZnO, graphite, or LTO anode, a cathode such as a LiFePO ₄ , LiCoO ₂ , sulfur, or Ag cathode. And a separator system with three low ion resistance layers. As shown in FIG. 10F, a first low ionic resistance layer such as a very porous layer (eg, ≧ 80%) is provided between the anode and the first high mechanical strength layer to form a very porous layer ( For example, a second low ionic resistance layer such as ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer, and a second layer such as a very porous layer (for example, ≧ 80%) is provided. 3 A low ionic resistance layer is provided between the second high mechanical strength layer and the cathode. In the electrochemical cell of FIG. 10F, the first high mechanical strength layer and the second high mechanical strength layer are independently mechanical resistant, such as a perforated metal layer having one or more insulating coatings, such as PE or PP coatings. Including chemical, and heat resistant electrical insulation layers.

FIG. 10G is an electrochemical cell with a separator that provides a cross-sectional view of the electrochemical cell in which the shape memory effect of the two high mechanical strength layers results in very good mechanical contact between the separator and the electrode. A schematic diagram is provided. The electrochemical cell has two high mechanical strengths with complementary opening patterns, such as an anode such as a silicon, Li, Zn, ZnO, graphite, or LTO anode, a cathode such as a LiFePO ₄ , LiCoO ₂ , sulfur, or Ag cathode. And a separator system with three low ion resistance layers. The overall geometry of the electrochemical cell in FIG. 10G is similar to that shown in FIG. 10F, with a first low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), as the anode. A second low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer. And a third low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), is provided between the second high mechanical strength layer and the cathode. However, in the electrochemical cell of FIG. 10G, the first high mechanical strength layer and the second high mechanical strength layer are independently mechanically resistant to a shape memory effect such as a perforated nitinol layer optionally coated with PE or PP. Including chemical, and heat resistant electrical insulation layers.

FIG. 10H is an electrochemical cell having a separator, where the superelastic and / or shape memory effect of the two high mechanical strength layers results in very good mechanical contact between the separator and the electrode. A schematic diagram providing a cross-sectional view is provided. In one embodiment of this embodiment, for example, a high degree of electrical contact is provided between the solid electrolyte and the cathode. Electrochemical cells include anodes such as silicon, Li, Zn, ZnO, graphite, or LTO anodes, cathodes such as LiFePO ₄ , LiCoO ₂ , sulfur, Ag, carbon-air, carbon-water cathodes, and complementary opening patterns. Separator system with two high mechanical strength layers having three, three low ionic resistance layers, and a solid electrolyte layer such as a LISICON or PEO (polyethylene oxide) layer. The overall geometry of the electrochemical cell in FIG. 10H is similar to that shown in FIGS. 10B, 10C, and 10D, with the first such as a very porous layer (eg, ≧ 80%). A low ionic resistance layer is provided between the anode and the first high mechanical strength layer, and a second low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), is provided between the first high mechanical strength layer and the second high mechanical strength layer. A third low ionic resistance layer such as a very porous layer (for example, ≧ 80%) provided between the high mechanical strength layer and the second high mechanical strength layer and the cathode, and a LISICON or PEO layer A solid electrolyte layer is provided between the third low ion resistance layer and the cathode so that ions can be transported to the cathode surface. However, in the electrochemical cell of FIG. 10H, the high mechanical strength layer is a mechanical, chemical and heat resistant superelastic or shape memory effect such as a perforated nitinol layer that can optionally be coated with PE or PP. It is an electric insulation layer. Similar to the description associated with FIG. 10B, the incorporation of a solid electrolyte layer (eg, a LIICON or PEO layer) is desirable for cathode protection, eg, with the components of the electrochemical cell such as the cathode surface and electrolyte components other than the solid electrolyte. Useful for protection from chemical reactions. In some embodiments, the solid electrolyte layer (e.g., the LISICON layer) is disposed on the first side of the electrochemical cell having the first electrolyte from the second side of the electrochemical cell having a second electrolyte different from the first electrolyte. Providing a separate chemical barrier layer, embodiments of this aspect may thus provide a means of integrating two separate electrolytes, each tailored specifically to the selected anode and cathode compositions.

FIG. 10I is an electrochemical cell having a separator, where the superelastic and / or shape memory effect of the two high mechanical strength layers results in very good mechanical contact between the separator and the electrode. A schematic diagram providing a cross-sectional view is provided. In one embodiment of this aspect, for example, a high degree of electrical contact is provided between the solid electrolyte and the cathode. Electrochemical cells include anodes such as silicon, Li, Zn, ZnO, graphite, or LTO anodes, cathodes such as LiFePO ₄ , LiCoO ₂ , sulfur, Ag, carbon-air, carbon-water cathodes, and complementary opening patterns. A separator system with two high mechanical strength layers having three, three low ionic resistance layers, and a solid electrolyte layer such as a LISICON or PEO layer. The overall geometry of the electrochemical cell in FIG. 10I is similar to that shown in FIGS. 10B, 10C, and 10D, with a first such as a very porous layer (eg, ≧ 80%). A low ionic resistance layer is provided between the anode and the first high mechanical strength layer, and a second low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), is provided between the first high mechanical strength layer and the second high mechanical strength layer. Provided between the high mechanical strength layer and a third low ionic resistance layer such as a very porous layer (for example, ≧ 80%) provided between the second high mechanical strength layer and the cathode, such as a LISICON layer A solid electrolyte layer is provided between the third low ion resistance layer and the cathode so that ions can be transported to the cathode surface. However, in the electrochemical cell of FIG. 10I, the high mechanical strength layer is a mechanical, chemical, and heat resistant electrical insulating layer that exhibits superelastic and / or shape memory effects, such as a porous shape memory polymer layer. is there. Similar to the description associated with FIG. 10B, the incorporation of a solid electrolyte layer (eg, a LIICON or PEO layer) is desirable for cathode protection, eg, with the components of the electrochemical cell such as the cathode surface and electrolyte components other than the solid electrolyte. Useful for protection from chemical reactions. In some embodiments, the solid electrolyte layer (eg, a LISICON or PEO layer) is a second side of an electrochemical cell having a second electrolyte different from the first electrolyte on the first side of the electrochemical cell having the first electrolyte. It provides a chemical barrier layer that separates from the side, and thus can provide a means of integrating two separate electrolytes, each tailored specifically to the selected anode and cathode compositions.

FIG. 10J shows an electrochemical cell having a separator, in which the conductive side of the separator breaks the electronic contact between the anode particles and the current collector and reduces the performance of the electrochemical cell, etc. 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that reduces anode loss. FIG. The electrochemical cell comprises an anode, such as a silicon anode, a cathode, such as a LiFePO ₄ or LiCoO ₂ cathode, and a separator system with two high mechanical strength layers and three low ionic resistance layers with complementary opening patterns. . The overall geometry of the electrochemical cell in FIG. 10J is similar to that shown in FIG. 10F, with the first low ionic resistance layer such as a very porous layer (eg, ≧ 80%) as the anode. A second low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer. And a third low ionic resistance layer, such as a very porous layer (eg, ≧ 80%), is provided between the second high mechanical strength layer and the cathode. However, in the electrochemical cell of FIG. 10J, the first high mechanical strength layer includes a mechanical, chemical and heat resistant electrical insulating layer positioned proximate to the anode, such as a perforated metal layer, 2 The high mechanical strength layer includes a mechanical, chemical and heat resistant electrical insulation layer positioned proximate to the cathode, such as a perforated Kapton layer.

FIG. 10K is an electrochemical cell having a separator, in which the conductive side of the separator adjacent to the anode breaks the electronic contact between the anode particles and the current collector and degrades the performance of the electrochemical cell by reducing the performance of the electrochemical cell. 1 provides a schematic diagram that provides a cross-sectional view of an electrochemical cell that reduces anode loss, such as in large deformations. In one embodiment of this aspect, the conductive side adjacent to the cathode increases the conductivity of the cathode, resulting in a longer life cycle, greater power and thicker cathode, and higher energy cathode, and thus a better electrochemical cell. Obtainable. The electrochemical cell comprises an anode, such as a silicon anode, a cathode, such as a LiFePO ₄ or LiCoO ₂ cathode, and a separator system with three high mechanical strength layers and three low ionic resistance layers having complementary opening patterns. . As shown in FIG. 10K, a first low ionic resistance layer such as a very porous layer (for example, ≧ 80%) is provided between the anode and the first high mechanical strength layer to form a very porous layer ( For example, a second low ionic resistance layer such as ≧ 80%) is provided between the first high mechanical strength layer and the second high mechanical strength layer, and a second layer such as a very porous layer (for example, ≧ 80%) is provided. 3 A low ion resistance layer is provided between the second high mechanical strength layer and the third high mechanical strength layer. In the electrochemical cell of FIG. 10K, the first high mechanical strength layer and the third high mechanical strength layer positioned in the vicinity of the anode and the cathode are respectively mechanical resistance, chemical resistance, and heat resistance such as a porous metal layer. The second high mechanical strength layer provided between the first high mechanical strength layer and the second high mechanical strength layer includes mechanical resistance, chemical resistance, and heat resistance, such as a perforated kapton layer. An electrically insulating and ionically conductive layer.

  11A and 11B provide examples of porous pattern layer designs for some separator systems of the present invention, such as layer F in FIGS. 2-10A. In the embodiment shown in FIGS. 11A and 11B, for example, there are alternating porous regions (shown schematically as stippled regions) and solid regions (shown schematically as filled regions). In these embodiments, the layer (s) R may provide an opening pattern that is the inverse of the design of the layer F. In FIGS. 11A and 11B, the pattern is characterized by alternating rectangular porous regions and solid regions.

High performance inexpensive rechargeable lithium battery: Separator and electrode design The highest energy batteries known so far use metals such as zinc and lithium that are inexpensive and have very high energy / power density. On the other hand, charging these batteries poses a significant safety hazard. A requirement to mitigate safety concerns is a very robust but highly conductive separator that can resist dendrite formation, accidents, and thermal runaway.

Using engineering methods for assembling the separator and electrodes, the separator system of this example provides significant improvements in safety, durability, power and energy performance in various battery chemistries. One approach of the present invention is to apply engineering knowledge and methods to the most efficient chemistry used in the battery industry. As shown in this example, the present invention provides an easy-to-manufacture method for making ultra-safe and high-capacity separators. A coin cell made of commercially available lithium metal, LiFePO ₄ , and the separator system demonstrates conductivity, solid mechanical strength, and a working temperature range of −40 ° C. to 200 ° C. comparable to conventional Celgard separators. The separator system of this example can be the main part of a Li-ion, Li-air, zinc-manganese, or zinc-air battery.

  The goal of certain aspects of the invention is to improve the rechargeability, safety, and high cycle life of existing non-rechargeable high energy chemistries such as lithium metal and zinc batteries, especially in practical scale batteries. It is to provide an advanced electrochemical system for high energy rechargeable metal-air batteries that provides an economic solution to the accumulation problem.

  Many modern lithium batteries are not rechargeable primarily due to dendrite formation that can lead to internal short circuits and fire and explosion. At the same time, silicon as a potentially high-energy anode can undergo a very large shape change with the current collector without the use of very expensive nanosilicon (not expandable) carefully grown in the preferred direction. Losing electrical contact. Many different electrolytes and additives have been tested and have not been useful in industrial level systems. In recent years, various solid electrolytes have been introduced to improve safety, but these have orders of magnitude lower conductivity compared to liquid electrolyte-separator systems, and fatigue after very few cycles, Performance is degraded due to cracking and loss of electrode-electrolyte contacts.

Using a novel expandable process, embodiments of the present invention have a highly rigid material that resists dendrite growth (e.g., a modulus greater than 1 GPa and a temperature range of -200C to 400C). Provide a porous separator system (eg, a conductivity of 10 ⁻² S / cm or higher for a liquid electrolyte at room temperature). Embodiments of the separator system provide a new device structure that enables high energy, low cost, practical scale batteries with a variety of chemistries. Embodiments of the separator system also provide transportation batteries that are free of accidents. Experimental results show, for example, that a battery incorporating the separator system can achieve more than 5,000 cycles with no or minimal capacity loss. In addition, some of the separator systems can be easily incorporated into the casting and roll-to-roll processing methods already used in current lithium battery manufacturing.

  An important feature of certain embodiments of the present invention is a multilayer separator system that simultaneously provides high conductivity and high safety. FIG. 12 shows a schematic diagram of a cross-sectional view of an electrochemical cell including the separator system of the present invention. As shown in FIG. 12, the electrochemical cell comprises an anode (3) and a cathode (4) separated from each other by a separator system (5). In this embodiment, the separator system (5) comprises a plurality of perforated layers (1 and 1 ′) comprising a tough material and having an opening pattern, and a plurality of frames and / or highly porous layers (2). With layers. The high modulus of the perforated layer of separator material prevents dendrites from penetrating the barrier directly. FIG. 14 provides an example of an opening pattern useful in the perforated layer of the separator system of the present invention. As shown in FIG. 14, the perforated layer of the separator system can have a circular opening. FIG. 14 also shows a complementary pattern of perforated layers useful for preventing dendrite growth, short circuits, and mechanical failure. For example, panels A and B provide complementary opening patterns that do not overlap when provided in the offset arrangement of a particular separator system. Panel C schematically shows the overlapping pattern of panels A and B, which indicates that the offset arrangement does not result in overlapping openings. Similarly, panels F and G provide complementary opening patterns that do not overlap when provided with the offset arrangement of a particular separator system. Similarly, panels H and I provide complementary opening patterns that do not overlap when provided with the offset arrangement of a particular separator system. Similarly, panels J and K provide complementary opening patterns that do not overlap when provided with the offset arrangement of a particular separator system. Similarly, panels L and M provide complementary rectangular opening patterns that do not overlap when provided in the offset arrangement of a particular separator system.

The large number of openings in the perforated layer ensures high conductivity of the separator, and the offset arrangement of holes in the continuous layer ensures that there is no direct path between the electrodes. The force from the high mechanical strength layer to the dendrite slows down or stops the dendrite growth. In electrochemical cells, this greatly improves cell performance. FIG. 13 provides a schematic illustrating potential trajectories of dendrite growth in the electrochemical cell of the present invention. In this figure, the dendrite is shown as a curve extending from the anode to the cathode. As shown in FIG. 13, the dendrite must be bent multiple times to cause a short circuit through the perforated layer. From a strictly mechanical point of view, the modulus of lithium (5 GPa) is orders of magnitude too high to allow continuous bending of dendrites at short lengths (less than 0.1 mm), bending a linear beam. The energy required for

Where E is the modulus of elasticity, I is the moment of inertia, and R (x) is the curvature at each point, and finally L is the length of the element. From a chemical engineering point of view, dendrites cannot overcome such complex growth pathways because of too much dynamic frustration. A layered separator system comprising a perforated layer with a complementary opening pattern effectively prevents dendrite formation and thus prevents short circuits. The materials and fabrication methods required for such composite separator systems are compatible with the present battery fabrication infrastructure and allow for low cost incorporation into current battery manufacturing. The present invention provides a cost effective and safe high energy lithium battery suitable for load leveling in a very slow charge (eg, C / 10) and very fast discharge (eg, 4C) power grid. The present invention also provides a process for making a layered separator that provides an industrially friendly battery characterized by liquid electrolyte conductivity, solid electrolyte safety, high cycle life, and low cost.

  The electrochemical system of the present invention is also compatible with the use of working electrodes such as prestressed electrodes. Lithium metal, when compressed in the out-of-plane direction, exhibits significantly better performance by leveling its surface (less moss and less dendrite). Also, out-of-plane compression of the silicon anode results in much better contact with the current collector and a much longer life cycle. This aspect of the invention can also be useful for solid state batteries by maintaining good contact between the electrode and the solid electrolyte and improving cycle life and performance.

To further demonstrate the beneficial attributes of the present invention, over 100 coin cells incorporating a composite layer separator system were fabricated and evaluated. Some of the tested separators are currently 0.125 mm thick compared to 0.025 mm Celgard and retain 75% capacity at C / 2. Safety tests involving blunt tip nails and high current cycle charging, 55 mA / cm ² at 300 cycles show that the separator system is robust and the battery does not cause an internal short circuit. Furthermore, in contrast to a fully destroyed 5-layer Celgard separator (0.125 mm thick), there is no measurable degradation or capacity loss after several hundred cycles. The present invention includes a separator system having a total thickness of 0.075 mm. The present invention includes a 0.025 mm thick roll of separator system useful for a 10 kWh pack of cylindrical 18650 lithium metal battery with 400 Wh / kg energy and 5000 cycles.

  Grid-level energy storage is currently accounted for by pumping, exceeding 99% of current electricity storage, which is possible in only a few limited sites and applications, and the growing demand for electricity storage in society. Not suitable for. Other solutions have major drawbacks. Compressed air technology has a very low repetition efficiency of less than 20%. Electrochemical capacitors and flywheels have a very low energy / cost ratio. Flow batteries used as a combination of high power and high energy are very complex and expensive. Current batteries also have a high cost / energy ratio and cost / power ratio (approximately $ 1 / Wh). Modern high energy lithium-metal, metal-air, and nanosilicon chemistry have significant safety / cost issues as described above.

  In some embodiments, the separator-electrode design of the present invention allows a range of rechargeable high energy chemistry that is not currently considered safe and / or has a short cycle life. Using industrial manufacturing methods (eg, CNC, molding, casting), the present invention combines electrochemistry with engineering to address the safety issues associated with modern battery technology. The separator system in combination with high energy electrodes provides a high energy battery with industrial scale safety and high cycle life for grid storage and also for electric vehicles.

  The system and method is scalable and industrially friendly. Improved separator performance can be achieved in several ways according to the present system and method. Improving conductivity by creating smaller holes (0.010 mm to 0.100 mm) and using thinner layers (0.005 mm) is a useful technique for utilizing high performance systems. In addition, separator systems that provide increased safety can be utilized using maintenance of the required offset alignment and attachment of the layers by heating at the boundaries and other selected areas.

FIG. 15 illustrates the charge capacity and discharge as a function of cycle number for an electrochemical cell having (A) a multilayer separator system of the present invention having a total thickness of 125 microns and (B) a Celgard separator having a thickness of 25 microns. A plot of capacity (mAh / g) is provided. The evaluated CR 2032 coin cell is made of a 0.5 mm thick Li foil anode, a LiFePO ₄ (0.0142 g) cathode, and 1M LiPF ₆ in EC: DEC: DMC (1: 1: 1). The voltage limits are 3v (discharge) and 4v (charge). Chemical conversion, 3 cycles at C / 24, and C / 2 cycle charge are distinguishable from a sudden drop in capacity. The upper line shows a separator made of two perforated Kapton layers as high mechanical strength layers and three perforated Celgard 2325 layers as low resistance layers. The bottom line shows a separator made of two perforated Kapton layers as high mechanical strength layers and three Celgard 2325 layers as low resistance layers. The cell is tested at room temperature. No measurable capacity drop was observed after 40-50 cycles. The experimental results shown in FIG. 15 indicate that the separator provides low resistance and is therefore compatible with a range of electrochemical systems.

FIG. 16 shows (B) charging as a function of cycle number for an electrochemical cell with a multilayer separator system of the present invention, a Li metal anode, and a LiCoO ₂ cathode, compared to an electrochemical cell with a conventional separator. A plot of capacity and discharge capacity (mAh / g) is provided. The electrochemical cell was a coin cell and was evaluated with a discharge rate of C / 2. The evaluated CR 2032 coin cell is made of a 0.5 mm thick anode of Li foil, a 0.1 mm thick cathode of LiFePO ₄ and 1M LiPF ₆ in EC: DEC: DMC (1: 1: 1). The voltage limits are 3v (discharge) and 4.2v (charge). Conversion, 5 cycles at C / 24, and C / 2 cycle charging are distinguishable from sudden capacity declines. Red lines (indicated by letter B) 1, 5, 6 indicate cells made of two perforated Kapton layers (2 mm diameter holes) as high mechanical strength layers and three Celgard 2325 layers as low resistance layers . Blue lines (indicated by the letter A) 2 and 3 represent reference electrodes formed by providing a perforated kapton between two Celgard layers. The cell is tested at room temperature. The cell was cycle charged at C / 2, then cycle charged for several cycles at C / 24, and then cycle charged again at C / 2. The experimental results show that the capacity loss was not likely due to the chemical reaction in the cell, but likely due to the resistance of the perforated Kapton layer of the evaluated electrochemical cell. FIG. 16 shows that, depending on the experimental conditions, a uniform pore distribution and thus smaller pores are required to reach good capacity in the cell.

FIG. 17 shows (B) an electrochemical cell having a conventional separator having a thickness of 75 microns and (c) a Celgard separator having a thickness of 25 microns. 3 provides a plot of charge capacity and discharge capacity (mAh / g) as a function of cycle number for an electrochemical cell with a metal anode and a LiCoO ₂ cathode. The electrochemical cell was a coin cell and was evaluated with a discharge rate of C / 2. The evaluated CR 2032 coin cells consist of a 0.5 mm thick anode of Li foil, a 0.1 mm thick cathode of LiFePO ₄ and 1M LiPF ₆ in EC: DEC: DMC (1: 1: 1). The voltage limits are 3v (discharge) and 4v (charge). Conversion, 5 cycles at C / 24, and C / 2 cycle charging are distinguishable from sudden capacity declines. Lines I and H show cells made of a single Celgard layer. Lines A, B and C show a separator made of two perforated Kapton layers as high mechanical strength layers and three Celgard 2325 layers as low resistance layers. Lines F and D show a reference electrode made with a perforated Kapton layer between two Celgard layers. The cell was tested at room temperature. The test demonstrates the importance of having a thin separator to reach high capacity in the cell.

FIG. 18 provides a schematic diagram illustrating the electrochemical cell of the present invention having a multilayer separator with three high mechanical strength layers having a complementary opening pattern, an anode, and a cathode. FIG. 19 provides a schematic diagram showing the trajectory of Li ⁺ ions passing through the multilayer separator shown in FIG. Although Li ⁺ ions can efficiently pass through the multilayer separator shown in FIG. 19, dendrites cannot follow the same trajectory and are thus prevented in certain embodiments of the invention. Furthermore, the force from the high mechanical strength layer slows or stops the dendrite growth.

  FIG. 20 provides a plot of cell voltage (V vs. Li) against cycle time (hours) for constant current lithium stripping from two symmetrical (5/9) inch lithium chips.

  FIG. 22 shows plots of current [ampere] versus time [seconds] (top) and voltage [v] versus time [seconds] (bottom) for the experiment of FIG. This shows the red line at the top.

23-30 provide photographs of perforated layers useful in some embodiments of the separator system. FIG. 23 is a photograph of, for example, different separator materials (5-Celgard separator: a) and new separators b) -d) after several days of cycle charging at high current, a) 5-Celgard separator ( Upper left to lower right: Li ⁺ Celgard, VC Gelgard, stainless steel current collector), b) Celgard layer between two perforated Kapton layers, c) Celgard in contact with lithium electrode, d) perforated Kapton. FIG. 24, for example, provides a photograph of a conventional separator (Celgard) where the lithium dendrite was pierced and destroyed. As shown, the separator is no longer recognized. Bottom) The lithium dendrite could not penetrate the new separator. As shown here, the Kapton layer of the new separator is intact, but the Celgard on the right side of the Kapton layer is destroyed. 25 and 26 are photographs of a 1 millikapton film prepared by laser cutting, for example, for use in the separator system of the present invention.

FIG. 23 shows two Kapton layers as high strength layers and a low resistance layer adjacent to them as compared to five Celgard layers (0.125 mm thick) as reference separators for a ½ inch diameter in-house fabricated cell. A layer of a new separator (0.125 mm thick) made of three Celgard layers. Celgard 2325 is used. The cell is made of 0.75 mm Li foil as the electrode and 1M LiPF ₆ in EC: DEC: DMC (1: 1: 1) from Novolte as the electrolyte. Each Kapton hole is 2 mm in diameter. The cell was tested at room temperature and cycle charged at 55 mA in a 45 minute charge / discharge cycle in an argon filled dry box (H ₂ O <0.5 ppm), (a) reference separator indicates a 5-Celgard reference separator; The cell is short-circuited, (b) shows a new separator, and the cell is not short-circuited. (B1) New separator: Celgard in contact with the lithium electrode shows severe damage, (b2) New separator: Celgard between the two perforated Kapton layers is intact, (b3) New separator: Perforated Kapton Is intact, maintains its structural integrity and prevents any short circuit. This figure shows that the multilayer separator can prevent dendrite short-circuiting and prevent damage even at very high currents. FIG. 24 (reduction) is the same as FIG. 23 (enlargement). The top and bottom graphs show two adjacent layers for each design. Figures 25-30 show some examples of high strength layer designs made of Kapton. The hole is formed by laser cutting. The size of each layer is 1/2 inch. The holes are 1 mm in diameter and 2 mm in diameter. FIG. 21 provides plots of current [mA] versus time “hours” and voltage versus Li [v] versus time [hours].

Lithium batteries present embodiment having a multilayer separator system provides a description of an example of a lithium battery having a multilayer separator system of the present invention.

Example A: In this example, two Kapton membrane layers, each 25 micrometers thick, are used in the separator system. Each layer is perforated with Cartesian (vertical-horizontal) periodic holes each having a diameter of 1 mm and a distance between the walls of 1 mm. A 25 micrometer Celgard layer is placed between the two Kapton layers. A 25 micrometer Celgard layer is placed between each Kapton layer and the adjacent electrode. The electrodes are LiCoO ₂ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example B: In this example, two Kapton membrane layers, each 25 micrometers thick, are used in the separator system. Each layer is formed with a Cartesian (vertical-horizontal) periodic hole having a diameter of 1 mm and a distance between walls of 1 mm for use in the separator system. A 25 micrometer Celgard layer is placed between the two Kapton layers. A 25 micrometer Celgard layer is placed between each Kapton layer and the adjacent electrode. The electrodes are LiCoO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example C: In this example, two Kapton membrane layers, each 25 micrometers thick, are used in the separator system. Each layer is perforated with Cartesian (vertical-horizontal) periodic holes each having a diameter of 1 mm and a distance between walls of 1 mm, and is used in a separator system. A perforated Celgard layer, 25 holes thick and 3 holes each 1/8 inch, is placed between the two Kapton layers. A perforated Celgard layer having three holes each of 25 micrometers thickness and 1/8 inch is placed between each Kapton layer and the adjacent electrode. The electrodes are LiCoO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example D: In this example, two Kapton membrane layers, each 25 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is perforated with Cartesian (vertical-horizontal) periodic holes each having a diameter of 1 mm and a distance between the walls of 1 mm. A 25 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 25 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are LiCoO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example E: In this example, two Kapton membrane layers, each 25 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is perforated with Cartesian (vertical-horizontal) periodic holes each having a diameter of 1 mm and a distance between the walls of 1 mm. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are LiCoO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example F: In this example, two stainless steel layers, each 5 micrometers thick, are used. A very thin electrical insulating layer is applied to the steel layer (here, 1 micrometer thick Teflon or Kapton can also be used). Each layer is provided with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.5 mm and a distance between walls of 0.5 mm. A 5 micrometer Celgard layer is placed between two stainless steel layers. A 5 micrometer Celgard layer is placed between each stainless steel layer and the adjacent electrode. The electrodes are LiCoO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example G: In this example, two Kapton membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is drilled with Cartesian (vertical-horizontal) periodic holes each having a diameter of 1 mm and a distance between walls of 1 mm. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outer diameter and 1/2 inch inner diameter, is placed between the Kapton layer adjacent to the lithium metal film anode and the Li electrode. A 25 micrometer thick and 3/4 inch diameter LISICON layer is placed between the second Kapton and the air carbon electrode. The electrolyte on the Li side of LISICON is LiPF ₄ in the EC-DMC-PC-DME combination. The electrolyte on the air cathode side of LISICON is an aqueous electrolyte.

Example H: In this example, two PE films, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is formed with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.1 mm and a distance between the walls of 0.1 mm. A 25 micrometer thick 3/4 inch diameter LISICON layer is placed between the second PE and the air carbon cathode. The electrolyte on the Li side of LISICON is LiPF ₆ in the EC-DMC-PC-DME combination. The electrolyte on the air cathode side of LISICON is an aqueous electrolyte.

  Example I: In this example, two stainless steel layers, each 5 micrometers thick, are used. The steel layer is coated with a very thin electrical insulation layer (here 1 micrometer thick Teflon) on the inner surface (the side not facing the nearby electrode). Each layer is formed with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.1 mm and a distance between the walls of 0.1 mm. A 5 micrometer Celgard layer is placed between two stainless steel layers. A 5 micrometer Celgard layer is placed between each stainless steel layer and the adjacent electrode. The electrodes are partially lithiated Si and partially lithiated sulfur. Batteries with this separator are expected to exhibit longer cycle life and higher charge / discharge (power) rates.

  Example J: In this example, two stainless steel layers, each 5 micrometers thick, are used. The steel layer has a very thin electrical insulation layer of 1 micrometer thick Teflon on the inner surface (side not facing the nearby electrode) and 1 micrometer thick polyethylene glycol on the outer surface (side facing the nearby electrode). Apply. Each layer is formed with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.1 mm and a distance between the walls of 0.1 mm. A 5 micrometer cellulose separator layer is placed between two stainless steel layers. A 5 micrometer cellulose separator layer is placed between each stainless steel layer and the adjacent electrode. The electrodes are Li metal and sulfur. Polyethylene glycol coatings are expected to extend battery cycle life.

  Example K: In this example, two Kapton membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is formed with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.1 mm and a distance between the walls of 0.1 mm. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are a zinc anode and a carbon-based air cathode. The electrolyte is a 6M KOH aqueous solution.

  Example L: In this example, two PP membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is formed with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.1 mm and a distance between the walls of 0.1 mm. The electrodes are a zinc anode and a carbon-based air cathode. The electrolyte is a 6M KOH aqueous solution.

  Example M: In this example, two Kapton membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is perforated with an arbitrary hole pattern having a diameter of 0.1 mm and a distance between walls of 0.1 mm, with a porosity of 40% and an overlap of the hole patterns of less than 5% when overlapped. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are a zinc anode and a carbon-based air cathode. The electrolyte is a 6M KOH aqueous solution.

Example N: In this example, two Kapton membrane layers, each 25 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is perforated with an arbitrary hole pattern in which the diameter is 1 mm and the distance between the walls is 1 mm, the porosity is 40%, and the overlap of the hole patterns is less than 5% when overlapped. A 25 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 25 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are LiFePO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example O: In this example, two Kapton membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is provided with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.01 mm and a distance between walls of 0.01 mm. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are LiFePO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

Example P: In this example, two Kapton membrane layers, each 5 micrometers thick and 3/4 inch in diameter, are used in the separator system. Each layer is perforated with Cartesian (vertical-horizontal) periodic holes each having a diameter of 0.001 mm and a distance between walls of 0.001 mm. A 5 micrometer thick Celgard ring is placed between the two Kapton layers. A Celgard ring, 5 micrometers thick, 3/4 inch outside diameter and 1/2 inch inside diameter, is placed between each Kapton layer and the adjacent electrode. The electrodes are LiFePO ₄ and a lithium metal film. The electrolyte is LiPF ₆ in the EC-DMC-PC-DME combination.

  Example Q: Same as any of the above examples, where the layers are attached to each other by PEO and PvDF in several areas such as the outer part on each side.

  Example R corresponds to Example G when the LISICON is 5 micrometers and deposited on the Kapton layer on the air cathode side of the lithium-air cell.

In another example, the porous pattern layer has the following physical dimensions, composition, and mechanical properties.
Thickness: 125 microns, 75 microns, 50 microns, or 25 microns Tensile strength: 150 MPa isotropic (Celgard: 15MPA TD (transverse direction); 150MPA MD (longitudinal direction))
・ Porosity: 45%
-Elastic modulus: 2 GPa
・ Yield strength: 50 MPa
Density: about 1.3 g / cm ³
-MIT bending strength: 10,000 cycles-Elmendorf tear strength: 0.1 N
・ Graves tear strength: 15N
-Impact strength: 50N. cm
・ Shrinkage for 30 minutes at 150 ° C .: 0.2 (Celgard: 5% to 10%)
-Dielectric strength ASTM D-149-91: 250 V / m
-Dielectric constant: 3.5
-Thermal expansion coefficient: 20 ppm / ° C

An electrochemical cell with a multilayer separator having a porous pattern layer having these properties exhibits useful performance characteristics. Half cell [coin cell]: For example, when LiFePO ₄ | LP71 | Li was tested after 200 cycles at C / 5, the capacity was about 140 mAh / g from C / 2 mAh / g to 120 mAh / g. A force-displacement test using external pressure showed that the cell did not short but stopped functioning. Analysis of the separator system after 300 cycles at C / 2 showed no or near degradation and the separator system could be used in another cell.

  Tables 1 and 2 provide a summary of the physical dimensions and properties of the high mechanical strength layer and separator system of certain embodiments of the present invention.

The resistivity of the separator was tested in 1M LiPF ₆ EC: EMC (30:70 by volume). For electrochemical evaluation, the separator was characterized using a 1/2 inch coin cell electrochemical cell with an Al-Al electrode. The separators are made as celgard / porous kapton / celgard / porous kapton / celgard, each 25 μm thick.

Separator With Coated Metal Mesh In some embodiments, the separator system of the present invention comprises one or more porous pattern layers that are a coated metal layer, such as a metal mesh with an outer insulating coating. Embodiments of this aspect are beneficial for greatly extending battery life. In one embodiment, for example, a metal mesh (Al, nickel, copper, stainless steel) has a very high mechanical strength over a very wide temperature range, and a metal separator equalizes the cell temperature to It is a heat conductive material that greatly improves safety and life. In one embodiment, the microporous layer of the separator is an aluminum mesh layer coated with PTFE (eg, Al mesh, 40% opening: 3 layers of 5 micrometers each or 2 layers of 1/3 mil each), In one embodiment, PTFE is applied to the Al layer, eg, 2 micrometers thick on each side. In another embodiment, only the Al layer adjacent to the anode is coated. In another embodiment, the Al layer is coated and the side is provided in contact with the electrode.

[Description of Incorporation by Reference and Variations]
Cited references throughout the application, for example, patent documents, patent applications published, and non-patent documents, including other patents or equivalents issued or granted, or other sources, are not at least partially inconsistent with the disclosure of the present application. The entire contents of which are hereby incorporated by reference as if individually incorporated by reference to the extent (for example, a partially inconsistent cited reference is by reference other than a partially inconsistent part of the cited reference). (Quote).

  The terms and expressions used herein are intended as explanatory terms, not as restrictive terms, and use of such terms and expressions is not intended to exclude equivalents or portions of the features shown and described. It will be appreciated that various modifications are possible within the scope of the claimed invention. Thus, although the present invention is specifically disclosed by preferred embodiments, exemplary embodiments, and optional features, modifications and variations of the concepts disclosed herein can be used by those skilled in the art. It should be understood that such modifications and variations are considered to be within the scope of the present invention as defined by the appended claims. The specific embodiments described herein are examples of useful embodiments of the invention, and the invention may be implemented using numerous variations of the devices, device components, and method steps described herein. It will be apparent to those skilled in the art that this can be done. As will be apparent to those skilled in the art, methods and apparatus useful in the present methods can include a number of optional compositions and processing elements and steps.

  All patents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which this invention pertains. The references cited herein are hereby incorporated herein by reference in their entirety to indicate the highest level as of the date of filing, and this information is referred to herein if necessary. It is intended that the specific embodiments that are prior art can be excluded (eg, abandoned) as used in. For example, when claiming a compound, compounds known in the art, including certain compounds disclosed in the cited references (particularly cited patent references) disclosed herein, are included in the claims. It should be understood that this is not intended.

  When substituent groups are disclosed herein, it should be understood that all members of these groups and all subgroups and classes that can be formed using the substituents are disclosed separately. Where Markush groups or other classifications are used herein, it is intended that this disclosure individually include all members of the group and all possible combinations and subcombinations of that group. As used herein, “and / or” means that the list includes one, all, or any combination of items in the list separated by “and / or”, eg , “1, 2 and / or 3” means “1” or “2” or “3” or “1 and 2” or “1 and 3” or “2 and 3” or “1, 2, and 3 ””.

  Unless stated otherwise, the invention can be practiced using any combination or combination of components described or exemplified. As it is known that one skilled in the art may refer to the same material under different names, the specific material names are for illustration. Those skilled in the art can use methods, equipment elements, starting materials, and synthetic methods other than those specifically exemplified in the practice of the present invention without undue experimentation. All prior art known functional equivalents of such methods, equipment elements, starting materials, and synthetic methods are intended to be included in the present invention. Whenever a range is given herein, for example a temperature range, a time range, or a composition range, all intermediate and subranges and individual values included in that given range are included in this disclosure. Is intended.

  It should be noted that as used in this specification and the appended claims, the singular forms include the plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a cell” includes a plurality of such cells known to those skilled in the art or equivalents thereof. Similarly, the terms “one,” “one or more,” and “at least one” can be used interchangeably herein. It should also be noted that the terms “comprising”, “including”, and “having” can be used interchangeably. The expression “any of claims XX to YY” (where XX and YY refer to claim numbers) is intended to provide alternative forms of the dependent claims, and some embodiments Then, it can be exchanged for “described in any one of claims XX to YY”.

  Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, and suitable methods and materials are now described. Nothing herein is to be construed as an admission that the invention is not an antecedent of such disclosure due to prior inventions.

  Whenever a range, such as an integer range, a temperature range, a time range, a composition range, or a concentration range, is given herein, all intermediate and subranges contained within that given range and individual values Are intended to be included in this disclosure. As used herein, a range specifically includes the value given as the endpoint value of the range. As used herein, a range specifically includes all integer values in the range. For example, a range of 1-100 specifically includes 1 and 100 endpoint values. It should be understood that any subranges or individual values in a range or subrange that are included in the description herein can be excluded from the claims herein.

  As used herein, “comprising” is synonymous with “including,” “including,” or “characterizing” and is inclusive or non-limiting and includes any additional, undescribed elements or Do not exclude method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the claim component. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. In this specification, in particular the description of the term “comprising” in the description of the components of the composition or in the description of the elements of the device consists essentially of the described component or element, and also consists of the described component or element. And methods. The invention exemplarily described in the present specification can be appropriately implemented without any elements or limitations not specifically disclosed in the present specification.

  The terms and expressions used are intended to be explanatory terms rather than restrictive terms, and the use of such terms and expressions is not intended to exclude equivalents or portions of the features shown and described and is subject to various modifications. It will be appreciated that configurations are possible within the scope of the claimed invention. Thus, although the present invention has been specifically disclosed by preferred embodiments and optional features, modifications and variations of the concepts disclosed herein can be used by those skilled in the art, and such variations and variations Is to be considered within the scope of the invention as defined by the appended claims.

DESCRIPTION OF SYMBOLS 100 Multi-layer separator system 102 High mechanical strength layer 104 Opening 106 Offset broken line area 108 Arrow 110 Point 112 Overlapping area of opening

Claims (19)

A separator system for an electrochemical system,
A first high mechanical strength layer, the first high mechanical strength layer having a plurality of openings provided in a first pattern through the first high mechanical strength layer;
A second high mechanical strength layer, having a plurality of openings provided in a second pattern penetrating through the second high mechanical strength layer, wherein the second pattern is (a) from the first high mechanical strength layer With respect to the first pattern, there is no overlap between the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending vertically to the second high mechanical strength layer. (B) the opening of the first high mechanical strength layer and the second high machine along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer. A second high mechanical strength layer having an offset arrangement with respect to the first pattern such that an overlap of the strength layer with the opening is greater than 0% and 5% or less, and the first high mechanical strength layer and the first layer The second high mechanical strength layer includes the first high mechanical strength layer and the second high mechanical strength layer. Is positioned ions of the electrolyte provided in contact with the strength layer so as to be transported through the first high mechanical strength layer and the second high mechanical strength layer,
The first at least one of the high mechanical strength layer and the second high mechanical strength layer, at least, Ri Do of metal or ceramic,
The first high mechanical strength layer and the second high mechanical strength layer are independently selected in the range of Elmendorf tear strength in the range of 0.005N to 10N and Graves tear strength in the range of 10N to 500N. Has initial tear strength,
The initial tear strength refers to the resistance to tear when a tear is first formed,
The separator system , wherein the tear strength refers to resistance to tearing when the tear is expanded after the tear is formed .   2. The separator system according to claim 1, wherein the first pattern in (b) is a first periodic opening pattern having a first pitch and an opening interval, and the second pattern has the first pitch and the opening interval. A separator system having a second periodic opening pattern that is offset from the position of the opening of the first periodic opening pattern. The separator system according to claim 1, further comprising one or more low ion resistance layers provided on at least one side of the first high mechanical strength layer and the second high mechanical strength layer,
The separator system wherein the low ion resistance layer independently has an ion resistance of 20 Ωcm 2 or less.   4. The separator system according to claim 3, wherein at least one of the plurality of low ion resistance layers is a deposited layer deposited on at least one of the first high mechanical strength layer and the second high mechanical strength layer. The separator system, wherein at least one of the plurality of low ion resistance layers is a deposited layer deposited on an electrode of an electrochemical cell.   4. The separator system according to claim 3, wherein the one or more low ion resistance layers include a spacer provided between the first high mechanical strength layer and the second high mechanical strength layer. A separator system that separates the first high mechanical strength layer and the second high mechanical strength layer by a selected distance selected from a range of 10 nm to 1000 μm.   4. The separator system according to claim 3, wherein the one or more low ionic resistance layers are in contact with at least one of the first high mechanical strength layer and the second high mechanical strength layer, or in an electrochemical cell. A separator system comprising one or more frame layers in contact with at least one of the electrodes.   4. The separator system according to claim 3, wherein one or more chemical barrier layers are provided on at least one side of the first high mechanical strength layer, the second high mechanical strength layer, and the plurality of low ion resistance layers. And wherein the one or more chemical barrier layers comprise a solid electrolyte or a solid polymer electrolyte, the one or more chemical barriers independently through the one or more chemical barrier layers. Separator system that prevents the transport of undesirable chemical components to the positive or negative electrode.   8. The separator system according to claim 7, wherein the separator system is a component of an electrochemical cell having a negative electrode and a positive electrode, and the one or more chemical barrier layers include an ion conductive protective membrane, The ion conductive protective film provides a barrier between the first electrolyte in contact with the positive electrode and the second electrolyte in contact with the negative electrode, and the ion conductive protective film includes the negative electrode and the first electrolyte. Separator system that prevents contact with the electrolyte.   The separator system according to claim 1, wherein the first pattern and the second pattern of openings provide a porosity of the first high mechanical strength layer and the second high mechanical strength layer of 30% or more. .   2. The separator system according to claim 1, wherein the first high mechanical strength layer and the second high mechanical strength layer independently have an average thickness selected in a range of 5 μm to 1 mm.   The separator system according to claim 1, wherein the first high mechanical strength layer and the second high mechanical strength layer independently have a Young's modulus selected in a range of 500 MPa to 500 GPa.   2. The separator system according to claim 1, wherein the first high mechanical strength layer and the second high mechanical strength layer are independently selected in a yield strength selected in a range of 5 MPa to 1000 MPa and in a range of 10 Ncm to 1000 Ncm. Separator system having an impact strength and a tensile strength selected in the range of 50 MPa to 2 GPa.   2. The separator system according to claim 1, wherein any one of the first high mechanical strength layer and the second high mechanical strength layer is independently a metal, an alloy, a ceramic, polyacrylic acid (PAA), a crosslinked polyethylene (PEX). , XLPE), polyethylene (PE), polyethylene terephthalate (PET, PETE), polyphenyl ether (PPE), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polylactic acid (PLA), polypropylene (PP), polybutylene (PB), polybutylene terephthalate (PBT), polyamide (PA), polyimide (PI), polycarbonate (PC), polytetrafluoroethylene (PTFE), polystyrene (PS), polyurethane (PU), polyester (PE), acrylonitrile Butadiene steel (ABS), poly (methyl methacrylate) (PMMA), polyoxymethylene (POM), polysulfone (PES), styrene-acrylonitrile (SAN), ethylene vinyl acetate (EVA), styrene maleic anhydride (SMA), PVDF ( (Polyvinyl fluoride), PEO PVDF (mixture of PEO and PVDF), LIPON (lithium phosphorus oxynitride), LISON (LIthium Super Ionic Conductor), tetramethylammonium hydroxide pentahydrate (CH3) 4NOH · 5H2O, poly (ethylene oxide) (PEO), epichlorohydrin and copolymers of ethylene oxide P (ECH-co-EO) and poly (vinyl alcohol), PEO-PVA-glass fiber polymer electrolyte, zinc sulfide, silicon dioxide, PVA and PSA, polyethylene Separator system comprising one or more materials selected from polyethylene glycol, polypropylene glycol, polybutylene glycol, acrylic polyethylene glycol, acrylic polypropylene glycol, alkyl polybutylene glycol, or PVA materials, and combinations thereof. The separator system according to claim 1, further comprising one or more coatings provided on any of the first high mechanical strength layer and the second high mechanical strength layer,
The separator system, wherein the one or more coatings are non-conductive coatings. The separator system according to claim 1, wherein any one of the first high mechanical strength layer and the second high mechanical strength layer is independently a metal layer or a ceramic layer.   4. The separator system according to claim 3, wherein at least one of the one or more low ionic resistance layers comprises a ceramic or glass electrolyte, a polymer electrolyte, or another solid electrolyte. A negative electrode;
A positive electrode;
A first electrolyte provided between the positive electrode and the negative electrode;
An electrochemical cell comprising a separator system in contact with the first electrolyte and provided between the negative electrode and the positive electrode;
The separator system is positioned to transport ions of the first electrolyte between the positive electrode and the negative electrode;
The separator system includes:
(I) a first high mechanical strength layer, the first high mechanical strength layer having a plurality of openings provided in a first pattern through the first high mechanical strength layer;
(Ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating through the second high mechanical strength layer, wherein the second pattern comprises: (a) the first high mechanical strength layer The first pattern so that there is no overlap between the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending vertically from the strength layer to the second high mechanical strength layer Or (b) the opening of the first high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer and the first A second high mechanical strength layer having an offset arrangement with respect to the first pattern so that an overlap of the high mechanical strength layer with the opening is greater than 0% and not more than 20%, the first high machine The strength layer and the second high mechanical strength layer are configured to absorb ions of the first electrolyte. Is positioned so as to be transported through the serial first high mechanical strength layer and the second high mechanical strength layer,
The first at least one of the high mechanical strength layer and the second high mechanical strength layer, at least, Ri Do of metal or ceramic,
The first high mechanical strength layer and the second high mechanical strength layer are independently selected in the range of Elmendorf tear strength in the range of 0.005N to 10N and Graves tear strength in the range of 10N to 500N. Has initial tear strength,
The initial tear strength refers to the resistance to tear when a tear is first formed,
The tear strength refers to a resistance to tear when expanding a tear after the tear is formed .   The electrochemical cell according to claim 17, wherein the electrochemical cell is a lithium ion cell, a lithium metal anode cell or a zinc ion cell. An alkaline metal fuel cell,
A renewable anode comprising as a fuel a solid alkali metal and an alkali metal dissolved in a solvent;
A cathode structure comprising a stationary electronic conducting component, an ion conducting component comprising an electrolyte for alkali metal ions, and a fluid oxidant obtained from the operating environment of the cell;
A separator system provided between the anode and the cathode structure;
The separator system includes:
(I) a first high mechanical strength layer, the first high mechanical strength layer having a plurality of openings provided in a first pattern through the first high mechanical strength layer;
(Ii) a second high mechanical strength layer having a plurality of openings provided in a second pattern penetrating through the second high mechanical strength layer, wherein the second pattern comprises: (a) the first high mechanical strength layer The first pattern so that there is no overlap between the opening of the first high mechanical strength layer and the opening of the second high mechanical strength layer along an axis extending vertically from the strength layer to the second high mechanical strength layer Or (b) the opening of the first high mechanical strength layer along an axis extending perpendicularly from the first high mechanical strength layer to the second high mechanical strength layer and the first A second high mechanical strength layer having an offset arrangement with respect to the first pattern so that an overlap of the high mechanical strength layer with the opening is greater than 0% and not more than 20%, the first high machine The strength layer and the second high mechanical strength layer are formed by the electrolyte ions. 1 is positioned so as to be transported through the high mechanical strength layer and the second high mechanical strength layer,
The first at least one of the high mechanical strength layer and the second high mechanical strength layer, at least, Ri Do of metal or ceramic,
The first high mechanical strength layer and the second high mechanical strength layer are independently selected in the range of Elmendorf tear strength in the range of 0.005N to 10N and Graves tear strength in the range of 10N to 500N. Has initial tear strength,
The initial tear strength refers to the resistance to tear when a tear is first formed,
The tear strength refers to an alkali metal fuel cell that refers to a resistance to tearing when the tear is expanded after the tear is formed .